Vehicle seat cushion with inflatable support

ABSTRACT

A cushion is adapted to set on a seat pan included in a vehicle seat. The cushion includes an inflatable air bag in, for example, a lumbar-support device.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a U.S. national counterpart application ofinternational application serial No. PCT/US2010/057048 filed Nov. 17,2010, which claims priority to U.S. Provisional Patent Application No.61/266,044 filed Dec. 2, 2009. The entire disclosures ofPCT/US2010/057048 and U.S. Ser. No. 61/266,044 are hereby incorporatedby reference.

BACKGROUND

The present disclosure relates to a vehicle seat, and particularly to aseat including an expandable and contractable portion. Moreparticularly, the present disclosure relates to a vehicle seat includinga cushion having a variable shape.

SUMMARY

According to the present disclosure, a vehicle seat includes a seatback. The seat back includes a cushion comprising an inflatable airbladder. In illustrative embodiments, the vehicle seat also includes aseat bottom and the seat back that extends upwardly from the seat bottomand includes a frame behind the cushion.

In illustrative embodiments, the cushion includes a deformable elasticbed made of an elastomeric material. The cushion also includes one ormore inflatable air bladders made of the elastomeric material andcoupled to the deformable elastic bed.

In illustrative embodiments, the cushion comprises two monolithic sheetsthat are mated to form the deformable elastic bed and a pair ofinflatable air bladders. In one embodiment, the inflatable air bladdersreside only in a backrest included in the cushion. In anotherembodiment, the inflatable air bladders lie in the backrest and extendoutwardly into both of the angled left and right wings included in thecushion and arranged to flank the backrest.

In illustrative embodiments, the cushion comprises three monolithicsheets. The first and second sheets mate to form the deformable elasticbed. The second and third sheets mate to form a pair of inflatable airbladders. In one embodiment, the inflatable air bladders reside only ina backrest included in the cushion. In another embodiment, theinflatable air bladders lie in the backrest and extend outwardly intoboth of the angled left and right wings included in the cushion andarranged to flank the backrest.

In illustrative embodiments, the cushion includes a deformable elasticbed and a bladder system coupled to the deformable elastic bed. Thebladder system comprises an inflatable lumbar bladder located betweentwo flanking inflatable bolster bladders. The bladder system alsocomprises one or more inflatable massage bladders associated with theinflatable lumbar bladder. In use, each of the lumbar bladder andbolster bladders can be inflated separately or in combination at theoption of a passenger seated on the cushion to provide customized torsosupport. Also, each of the massage bladders associated with theinflatable lumbar bladder can be (1) inflated at the option of thepassenger to provide further customized lumbar support or (2) inflatedand deflated repeatedly in sequence and in accordance with a selectedinflation/deflation cycling plan to provide a back-massaging sensationto a seated passenger.

In illustrative embodiments, the cushion comprises three monolithicsheets. A first monolithic sheet lies on an underlying seat pan andcooperates with an overlying second monolithic sheet to form thedeformable elastic bed and each of the inflatable lumbar bladder and theinflatable bolster bladders. A massage unit lies above and cooperateswith the second monolithic sheet to form an inflatable massage bladderhaving an air chamber that is separate from air chambers included in theinflatable lumbar and bolster bladders. In illustrative embodiments,several separate massage units are coupled to the second monolithicsheet to form an array of inflatable massage bladders on an exteriorsurface of the inflatable lumbar bladder.

In illustrative embodiments, the deformable elastic bed includes acentral backrest bed section and the lumbar and massage bladders arelocated in a central bladder-receiving cavity formed in the centralbackrest bed section. The deformable elastic bed also includes left-wingand right-wing bed sections lying in spaced-apart diverging relation toone another to locate the central backrest bed section therebetween andto diverge in a direction extending away from the central backrest bedsection. In illustrative embodiments, one of the bolster bladders isarranged to lie in a left bladder-receiving cavity formed in theleft-wing bed section and another of the bolster bladders is arranged tolie in a right bladder-receiving cavity formed in the right-wing bedsection.

Additional features of the present disclosure will become apparent tothose skilled in the art upon consideration of illustrative embodimentsexemplifying the best mode of carrying out the disclosure as presentlyperceived.

BRIEF DESCRIPTION OF THE DRAWINGS

The detailed description particularly refers to the accompanying figuresin which:

FIG. 1 is a perspective and diagrammatic view of a vehicle seatincluding a seat bottom and a seat back comprising a cushion including adeformable elastic bed surrounding a pair of inflatable bladders (shownin phantom) that may be inflated by pressurized air coming from amanifold to expand the size of the inflatable air bladders relative tothe deformable elastic bed as suggested in FIG. 6 so that a lower back(lumbar) area of a passenger seated in the vehicle seat is supported;

FIG. 2 is an enlarged partial perspective and diagrammatic view of theseat back of FIG. 1, with portions broken away, suggesting that use ofan air pump and manifold to inflate each of the inflatable air bladdersto provide a pneumatic four-way lumbar-support system in the cushion,with portions of the deformable elastic bed broken away to reveal a pairof air-inlet conduits coupled to associated air-inlet ports formed in aright-side edge of each inflatable air bladder;

FIG. 3 is an exploded perspective assembly view of the seat back of FIG.1, showing that the seat back includes, from left to right, a cushioncover, a cushion including a multi-chambered deformable elastic bedformed to include a bladder-receiving cavity containing first and secondinflatable air bladders, and a seat pan configured to couple to aseat-pan support frame and to mate with a pad comprising the cushion andthe cushion cover;

FIG. 3 a is an exploded perspective assembly view of the cushion of FIG.3 showing that the cushion includes a monolithic first sheet, amonolithic second sheet in front of the monolithic first sheet, and apair of air-inlet conduits that are arranged to be mounted between themonolithic first and second sheets to provide independent passagewaysfor air to travel into the first and second inflatable air bladdersformed in the cushion;

FIG. 4 is an enlarged exploded assembly view of the components includedin the cushion shown in FIGS. 2-3 a showing a monolithic first sheetmade of an elastomeric material separated from a companion monolithicsecond sheet made of the elastomeric material before the two sheets aremoved toward one another along the illustrated dotted lines to mate andjoin together to form the cushion shown in FIG. 3 a;

FIG. 5 is a sectional and diagrammatic view taken along line 5-5 of FIG.2 showing the first inflatable air bladder in the deflated state on aportion of the underlying seat pan and showing four separate resilientdeformable posts formed in the first air chamber in response to matingengagement of each outwardly projecting dome included in an inner shellformed in the monolithic first sheet with a companion inwardlyprojecting dome included in an outer shell formed in the monolithicsecond sheet and showing (in phantom) an expansion perimeter defined bythe monolithic second sheet after it has moved away from the monolithicfirst sheet as shown in FIG. 6;

FIG. 6 is a view similar to FIG. 5 showing the first inflatable airbladder in an inflated state and movement of inwardly projecting domesincluded in an outer shell formed in the monolithic second sheet awayfrom companion outwardly projecting domes included in an inner shellformed in the monolithic first sheet;

FIG. 7 is a perspective and diagrammatic view of a vehicle seat inaccordance with another embodiment of the present disclosure suggestingthat a pair of inflatable air bladders formed in a cushion to extendfrom a left outer edge of a left wing of the cushion through a centralbackrest to a right outer edge of a right wing of the cushion may beinflated as suggested in FIG. 11;

FIG. 8 is an enlarged partial perspective and diagrammatic view of theseat back of FIG. 8, with portions broken away, suggesting that airprovided by an air pump directed through a manifold may be communicatedselectively into the first and second inflatable air bladders to providea pneumatic four-way torso-support system in the cushion;

FIG. 9 a is an exploded perspective assembly view of the seat back ofFIG. 7, showing that the seat back includes, from left to right, acushion cover, a cushion including a multi-chambered deformable elasticbed formed to include a bladder-receiving cavity containing first andsecond inflatable air bladders, and a seat pan configured to couple to aseat-pan support frame and to mate with a pad comprising the cushion andthe cushion cover;

FIG. 9 b is an exploded perspective assembly view of the cushion of FIG.9 a showing that the cushion includes a monolithic first sheet, amonolithic second sheet in front of the monolithic first sheet, and apair of air-inlet conduits that are arranged to be mounted between themonolithic first and second sheets to provide independent passagewaysfor air to travel into the first and second inflatable air bladdersformed in the cushion;

FIG. 10 is a sectional and diagrammatic view taken along line 10-10 ofFIG. 8 showing the first inflatable air bladder in a deflated state onthe underlying seat pan and showing six separate resilient deformableposts formed in the first air chamber in response to mating engagementof each outwardly projecting dome included in an inner shell formed inthe monolithic first sheet with a companion inwardly projecting domeincluded in an outer shell formed in the monolithic second sheet andshowing (in phantom) a portion of a passenger's torso supported by thecentral backrest section of the first inflatable air bladder included inthe cushion;

FIG. 11 is view similar to FIG. 10 showing the first inflatable airbladder in an inflated state and movement of inwardly projecting domesincluded in an outer shell formed in the monolithic second sheet awayfrom companion outwardly projecting domes included in an inner shellformed in the monolithic first sheet and suggesting that the passenger'storso (shown in phantom) is supported by the central backrest section,the left-wing section, and the right-wing section of the of the firstinflatable air bladder;

FIG. 12 is a perspective and diagrammatic view of a vehicle seat inaccordance with another embodiment of the present disclosure showingthat the vehicle seat includes a seat bottom and a seat back comprisinga cushion including a deformable elastic bed surrounding a pair ofinflatable bladders (shown in phantom) that may be inflated bypressurized air coming from a manifold to expand the size of theinflatable air bladders relative to the deformable elastic bed assuggested in FIG. 16 so that the lower back (lumbar) area of a personseated in the vehicle seat is supported;

FIG. 13 is an enlarged partial perspective and diagrammatic view of theseat back of FIG. 12, with portions broken away, suggesting use of anair pump and manifold to inflate each of the inflatable air bladders toprovide a pneumatic four-way lumbar-support system in the cushion, withportions of an outer auxiliary layer of the cushion broken away toreveal diamond and square shaped resilient support structures are formedwithin the inflatable air bladders, and with portions of the deformableelastic bed broken away to reveal a pair of air-inlet conduits coupledto associated air-inlet ports formed in a right-side edges of eachinflatable air bladder;

FIG. 14 is an exploded perspective assembly view of the seat back ofFIG. 12 showing that the seat back includes, from left to right, acushion cover, a cushion including a multi-chambered deformable elasticbed formed to include a bladder-receiving cavity containing first andsecond inflatable air bladders, and a seat pan configured to couple to aseat-pan support frame and to mate with a pad comprising the cushion andthe cushion cover;

FIG. 14 a is an exploded perspective assembly view of the cushion ofFIG. 14 showing that the cushion includes, from left to right, anauxiliary (third) sheet, a monolithic second sheet, a monolithic firstsheet, and a pair of air-inlet conduits that are arranged to be mountedbetween the auxiliary sheet and the monolithic second sheet to provideindependent passageways for air to travel into the first and secondinflatable bladders formed in the cushion;

FIG. 15 is a sectional and diagrammatic view taken along line 15-15 ofFIG. 13 showing the first inflatable air bladder in a deflated state andshowing four separate resilient deformable posts formed in the first airchamber in response to mating engagement of each outwardly projectingdome included in an inner shell formed in the monolithic first sheetwith a companion inwardly projecting dome included in an outer shellformed in the monolithic second sheet and showing (in phantom) anexpansion perimeter defined by the auxiliary sheet moving outwardly awayfrom the monolithic first and second sheets during inflation of theinflatable air bladder as suggested in FIG. 16;

FIG. 16 is a view similar to FIG. 15 showing the first inflatable airbladder in an inflated state and movement of inwardly projecting domesincluded in an outer shell formed in the monolithic second sheet awayfrom companion outwardly projecting domes included in an inner shellformed in the monolithic first sheet and showing that the firstinflatable air bladder is formed between the auxiliary sheet and themonolithic second sheet and that a series of spaced-apart resilientdeformable posts are formed in the monolithic first and second sheetsbelow the auxiliary sheet;

FIG. 17 is a perspective and diagrammatic view of a vehicle seat inaccordance with another embodiment of the present disclosure suggestingthat a pair of inflatable air bladders formed in a cushion to extendfrom a left outer edge of a left wing of the cushion through a centralbackrest to a right outer edge of a right wing of the cushion may beinflated as suggested in FIG. 21;

FIG. 18 is an enlarged partial perspective and diagrammatic view of theseat back of FIG. 17, with portions broken away, suggesting that airprovided by an air pump directed through a manifold may be communicatedselectively into the first and second inflatable air bladders to providea pneumatic four-way torso-support system in the cushion;

FIG. 19 a is an exploded perspective assembly view of the seat back ofFIG. 17 showing that the seat back includes, from left to right, acushion cover, a cushion including a multi-chambered deformable elasticbed and a pair of inflatable air bladders formed in the multi-chambereddeformable elastic bed, and a seat pan coupled to a seat-pan supportframe;

FIG. 19 b is an exploded perspective assembly of the cushion of FIG. 19a showing that the cushion includes, from left to right, an auxiliary(third) sheet, a monolithic second sheet, a monolithic first sheet, anda pair of air-inlet conduits that are arranged to be mounted between theauxiliary sheet and the monolithic second sheet to provide independentpassageways for air to travel into the first and second inflatable airbladders formed in the cushion;

FIG. 20 is a sectional and diagrammatic view taken along line 20-20 ofFIG. 18 showing the first inflatable air bladder in a deflated state onthe underlying seat pan showing six separate resilient deformable postsformed in the first air chamber in response to mating engagement of eachoutwardly projecting dome included in an inner shell formed in themonolithic first sheet with a companion inwardly projecting domeincluded in an outer shell formed in the monolithic second sheet andshowing (in phantom) a portion of a passenger's torso supported by thecentral backrest section of the first inflatable air bladder;

FIG. 21 is a sectional view similar to FIG. 15 showing the firstinflatable bladder in an inflated state and movement of inwardlyprojecting domes included in an outer shell formed in the monolithicsecond sheet away from companion outwardly projecting domes included inan inner shell formed in the monolithic first sheet and showing that thefirst inflatable bladder is formed between the auxiliary sheet and themonolithic second sheet so that the passenger's torso is supported bythe central backrest section, the left-wing section, and the right-wingsection of the first inflatable air bladder;

FIG. 22 is a perspective and diagrammatic view a vehicle seat inaccordance with another embodiment of the present disclosure showingthat the vehicle seat includes a seat bottom and a seat back comprisinga cushion including a deformable elastic bed surrounding a pair ofhalf-moon-shaped inflatable bolster bladders (shown in phantom), a pairof rectangle-shaped inflatable lumbar bladders (shown in phantom), andten square-shaped inflatable massage bladders (shown in phantom) thatmay be inflated separately by pressurized air coming from a manifold toexpand the size of the inflatable bladders relative to the deformableelastic bed as suggested in FIGS. 24 and 26 so that the cushion may beinflated as desired by a passenger sitting on the seat bottom;

FIG. 23 is an enlarged partial perspective and diagrammatic view of thecushion of FIG. 22 showing the cushion in a deflated state andsuggesting that an air pump and manifold may be used to inflate each ofthe inflatable air bladders so that a pneumatic back-support system isprovided in the cushion;

FIG. 23 a is a diagrammatic sectional view taken along line 23 a-23 a ofFIG. 23 while each of the first and second air bladders is in a deflatedstate;

FIG. 23 b is a diagrammatic sectional view similar to FIG. 23 a showingthe first air bladder in an inflated state while the second air bladderremains in a deflated state;

FIG. 24 is a view similar to FIG. 23 showing the cushion afterpressurized air has been admitted into a right bolster bladder, a toplumbar bladder, and a massage bladder coupled to a right side of the toplumbar bladder;

FIG. 24 a is a diagrammatic sectional view taken along lines 24 a-24 aof FIG. 24 while each of the first and second air bladders is in aninflated state;

FIG. 25 is a sectional view taken along line 25-25 of FIG. 23 showingthat a free-standing dome is arranged in the right bolster bladder andin the massage bladder to provide support to the passenger restingagainst the cushion when the bladders are deflated and showing (inphantom) an expansion perimeter defined by the inflatable bladders;

FIG. 26 is a sectional and diagrammatic view taken along line 26-26 ofFIG. 24 showing the right bolster bladder in an inflated state, the toplumbar bladder in an inflated state, and the massage bladder in aninflated state;

FIG. 27 is an exploded perspective assembly view of the seat back ofFIG. 22 showing that the seat back includes, from left to right, acushion cover, a cushion including a deformable elastic bed formed toinclude multiple massage-bladder cavities that contain ten square-shapedmassage bladders, two spaced-apart bolster bladders, and tworectangle-shaped lumbar bladders, and a seat pan configured to couple toa seat-pan support frame and to mate with a pad that comprises thecushion and the cushion cover;

FIG. 28 is an exploded perspective assembly view of the cushion of FIG.23 showing that the cushion includes, from left to right, a set ofmassage bladders, a monolithic second sheet on which the massagebladders are coupled thereto, and a monolithic first sheet that iscoupled to the monolithic second sheet to form the pair of bolsterbladders and the pair of lumbar bladders therebetween;

FIG. 29 is an exploded perspective assembly view of the cushion of FIG.23 suggesting that the set of ten massage bladders are arranged to liein associated massage-bladder cavities formed in the monolithic secondsheet and that the massage bladders are coupled to an outer surface ofthe monolithic second sheet;

FIG. 30 is an enlarged perspective view of one massage bladder includedin the set of massage bladder shown in FIG. 29; and

FIG. 31 is an exploded perspective assembly view of the massage bladderof FIG. 30 showing that the massage bladder includes, from top tobottom, a first expansion layer, a second expansion layer formed toinclude an air passageway, and a dome-shaped third expansion layerconfigured to mate with the outer surface of the monolithic second sheetas suggested in FIG. 29.

DETAILED DESCRIPTION

A vehicle seat includes a seat bottom and a seat back arranged to extendupwardly from the seat bottom as shown, for example, in FIGS. 1, 7, 12,17, and 22. In each of the embodiments disclosed herein, the seat backincludes a cushion comprising an inflatable air bladder. In theembodiments illustrated in FIGS. 1-11, two monolithic sheets made of anelastomeric material cooperate to form the cushion. In the embodimentsillustrated in FIGS. 12-21, three monolithic sheets made of anelastomeric material cooperate to form the cushion. In the embodimentillustrated in FIGS. 22-31, two monolithic sheets and several massagebladders made of elastomeric material cooperate to form the cushion.

In the embodiments shown in FIGS. 1-11, two monolithic sheets cooperateto form a cushion having a backrest flanked by left and right sidewings. In one embodiment shown in FIGS. 1-6, a pair of inflatable airbladders 21, 22 are located only in a backrest 88 included in cushion 14and flanked by left and right side wings 86, 90. In another embodimentshown in FIGS. 7-11, a pair of inflatable air bladders 121, 122 arelocated in left side wing 186, backrest 188, and right side wing 190included in cushion 114.

In the embodiments shown in FIGS. 12-21, three monolithic sheetscooperate to form a cushion having a backrest flanked by left and rightside wings. In one embodiment shown in FIGS. 12-16, a pair of inflatableair bladders 221, 222 are located only in a backrest 288 included incushion 214 and flanked by left and right side wings 286, 290. Inanother embodiment shown in FIGS. 17-21, a pair of inflatable airbladders 321, 322 are located in left side wing 386, backrest 388, andright side wing 390 included in cushion 314.

In the embodiments shown in FIGS. 22-31, two monolithic sheets cooperateto form a cushion having a backrest flanked by left and right sidewings. As shown in FIGS. 23, 24, and 27-29, a pair of rectangle-shapedinflatable lumbar bladders and 421, 422 several inflatable massagerbladders 430B are located only in a backrest 488 included in cushion414. Backrest 488 is flanked by a left and right side wings 486, 490 anda half-moon shaped inflatable bolster bladder 423, 424 is located ineach side wing 486, 490.

A vehicle seat 10, in accordance with the present disclosure, includesone occupant-support base 11 configured to provide a seat bottom andanother occupant-support base 12 configured to provide a seat backarranged to extend upwardly from the seat bottom as shown in FIG. 1. Inan illustrative embodiment, seat back 12 includes a cushion 14 includinga deformable elastic bed 16 and a pair of inflatable air bladders 21, 22as suggested in FIGS. 3-4. Deformable elastic bed 16 is configured tosupport a portion of a passenger seated on cushion 14 of seat back 12.Inflatable air bladders 21, 22 may be inflated using pressurized air toexpand in outward directions 38 from a deflated state shown in FIGS. 1,2, and 5 to an inflated state shown in FIG. 6 to provide adjustablelumbar support for a passenger seated in vehicle seat 10. Inflatable airbladders 21, 22 cooperate to form an adjustable pneumaticpassenger-support module 18 as suggested in FIGS. 1 and 2.

Deformable elastic bed 16 and inflatable air bladders 21, 22 are madefrom a suitable elastomeric material in an illustrative embodiment.Deformable elastic bed 16 and inflatable air bladders 21, 22 are made ofthe same elastomeric material in an illustrative embodiment. Inillustrative embodiments, an elastomeric material such as athermoplastics polyurethane (TPU) material is used.

Seat back 12 includes a cushion cover 20, a cushion 14, and a seat pan24 as shown, for example, in FIGS. 2 and 3. A seat-pan support frame 26may also be included in vehicle seat 10 to support a seat pan 24included in seat back 12 or seat bottom 11 as suggested in FIGS. 1 and3. Cushion 14 is anchored to underlying seat pan 24 using any suitablemeans and cushion cover 20 is coupled to cushion 14 and/or seat pan 24using any suitable means and arranged to cover deformable elastic bed 16and inflatable air bladders 21, 22 as suggested in FIGS. 1-3. It iswithin the scope of this disclosure to support cushion 14 using aconventional frame having suspension springs.

During use of adjustable pneumatic passenger-support module 18, a pumpcontroller 28 is used by a passenger to actuate a manifold 30 to directa source of pressurized air, such as an air pump 34 coupled to an airsource 29, to generate a pressurized air stream 36. Pressurized airsteam 36 is conducted through a pair of hoses 40 a, 40 b and thenthrough a pair of associated air-inlet conduits 44, 46 into air chambers48, 50 formed in inflatable air bladders 21, 22 as suggested in FIGS. 1,2, and 5. This causes inflatable air bladders 21, 22 to expand outwardlyin outward direction 38 to assume an inflated state as suggested in FIG.6. It is within the scope of the present disclosure to use any suitablefluid pressure management system to inflate and deflate inflatable airbladders 21, 22.

Cushion 14 illustratively includes a left wing 86, a backrest 88, and aright wing 90 as shown, for example, in FIGS. 1 and 2. Backrest 88 isconfigured to support a central portion of a passenger's torso. Leftwing 86 is configured to support a left portion of the passenger's torsoand right wing 90 is configured to support a right portion of thepassenger's torso. As shown in FIG. 2, first and second inflatable airbladders 21, 22 are arranged to lie in backrest 88 of cushion 14.

Deformable elastic bed 16 is formed to include a left-wing bed section91, a backrest bed section 92, and a right-wing bed section 93. As shownin FIG. 2, left-wing bed section 91 is arranged to lie in spaced-apartrelation to right-wing bed section 93 to locate backrest bed section 92therebetween. Illustratively, first and second inflatable air bladders21, 22 are positioned to lie in backrest bed section 92 of deformableelastic bed 16.

As shown in FIG. 3, a top portion 911, an intermediate portion 912, anda bottom portion 913 cooperate to form left-wing bed section 91.Intermediate portion 912 is arranged to interconnect top portion 911 andbottom portion 913. A top portion 931, an intermediate portion 932, anda bottom portion 933 cooperate to form right-wing bed section 93.

A top portion 921, an intermediate portion 922, and a bottom portion 923cooperate to form backrest bed section 92 as illustrated in FIG. 3.Intermediate portion 912 of backrest bed section 92 is arranged tointerconnect top portion 921 and bottom portion 923. As suggested inFIG. 3, first and second inflatable air bladders 21, 22 are positionedto lie above intermediate portion 922 of backrest bed section 92 betweentop portion 921 and bottom portion 923.

A monolithic first sheet 31 and a monolithic second sheet 32 are matedtogether to form deformable elastic bed 16 and first and secondinflatable air bladders 21, 22 as suggested in FIGS. 3 a and 4. Each ofmonolithic first and second sheets 31, 32 is made of an elastomericmaterial.

Monolithic first sheet 31 includes a first web 41, a first inner shell51 b, and a second inner shell 52 b as shown in FIG. 4. First web 41 isconfigured to form an inner portion of deformable elastic bed 16. Firstinner shell 51 b is configured to form an inner portion of firstinflatable air bladder 21. Second inner shell 52 b is configured to forman inner portion of second inflatable air bladder 22.

Monolithic second sheet 32 includes a second web 42, a first outer shell51 a, and a second outer shell 52 a as illustrated in FIG. 4. Second web42 is configured to form an outer portion of deformable elastic bed 16.First outer shell 51 a is configured to form an outer portion of firstinflatable air bladder 21. Second outer shell 52 a is configured to forman outer portion of second inflatable air bladder 22.

First inflatable air bladder 21 is formed to include first air chamber48 by mating portions of monolithic first and second sheets 31, 32 assuggested in FIGS. 5 and 6. As shown, for example, in FIG. 4, firstinner shell 51 b of first monolithic sheet 31 includes a shell wall 79 wand a shell plate 79 p as shown in FIGS. 5 and 6. Shell wall 79 w andshell plate 79 p cooperate to form a first basin 61 a and first outershell 51 a of second monolithic sheet 32 includes a shell wall 69 w anda shell plate 69 p. Shell wall 69 w and shell plate 69 p cooperate toform a first basin 61 b opening toward first basin 61 a. First shells 51a, 51 b are sealingly coupled to one another to cause first basins 61 a,61 b to communicate with one another to form first air chamber 48between first shells 51 a, 51 b as suggested in FIGS. 4-6.

Second air chamber 50 of second inflatable air bladder 22 is suggestedin FIG. 2 and is formed in a manner similar to first air chamber 48 offirst inflatable air bladder 21. Second inner shell 52 b of first web 41is formed to include a second basin 62 a and second outer shell 52 a ofsecond web 42 is formed to include a second basin 62 b opening towardsecond basin 62 a. Second shells 52 a, 52 b are sealingly coupled to oneanother to cause second basin 62 a, 62 b to communicate with one anotherto form second air chamber 50 between second shells 52 a, 52 b assuggested in FIGS. 2 and 4.

First inflatable air bladder 21 is also formed to include a firstair-intake port 71 opening into first air chamber 48 and mating withfirst air-inlet conduit 44 as suggested in FIGS. 2, 3 a, and 4-6. Firstshells 51 a, 51 b mate with one another along a first shell interface 54and cooperate to form first air-intake port 71 therebetween along firstshell interface 54 as shown, for example, in FIGS. 2, 5, and 6. Firstinner shell 51 b of first web 41 includes a continuous sealing edge 51bs that is interrupted by a port-forming edge 51 bpf as shown in FIG. 4.Similarly, first outer shell 51 a of second web 42 includes a continuoussealing edge 51 as interrupted by a port-forming edge 51 apf as shown inFIG. 4. When monolithic first sheet 31 is mated to monolithic secondsheet 32, sealing edge 51 bs of first inner shell 51 b is sealinglycoupled to sealing edge 51 as of first outer shell 51 a to form firstair chamber 48 and port-forming edge 51 apf of first outer shell 51 a isarranged to lie in stationary confronting relation to port-forming edge51 bpf of first inner shell 51 b to form first air-intake port 71therebetween as suggested in FIGS. 3 a-6.

As shown in FIG. 5, first inflatable air bladder 21 is shown in adeflated state with pressurized air stream 36 from manifold 30 beingturned OFF. A series of outwardly projecting domes 76 are formed infirst inner shell 51 b of monolithic first sheet 31 as shown best inFIGS. 4-6. A series of inwardly projecting domes 66 are formed in firstouter shell 51 a of monolithic second sheet 32 as shown best in FIGS.4-6. Domes 66 and 76 may be formed to have any suitable shape andfrustopyramidal shapes are shown as an example.

When first inflatable air bladder 21 is in the deflated stated, a firsttip 76T of dome 76 and a second tip 66T of dome 66 are arranged to liein confronting relation to one another as shown in FIG. 5. First tip 66Tis aligned above second tip 76T so that first tip 66T is supported bysecond tip 76T to cause a passenger resting on cushion 14 to besupported by the deflated inflatable air bladder 21. When firstinflatable air bladder 21 is inflated, monolithic second sheet 32 ispermitted to move away from monolithic first sheet 31 toward anexpansion perimeter 84 to cause first tip 66T of each dome 66 toseparate and move away from a companion second tip 76T of dome 76 assuggested in FIG. 5 and shown in FIG. 6.

Pressurized air stream 36 is communicated into first inflatable airbladder 21 through first air-inlet conduit 44. As an example, firstair-inlet conduit 44 is arranged to extend into first air-intake port 71and formed to include a passageway configured to provide means forconducting pressurized air from a source 34 into first air chamber 48 tochange first inflatable air bladder 21 from the deflated state shown inFIGS. 1, 2, and 5 to the inflated state shown in FIG. 6. In anillustrative embodiment, first air-inlet conduit 44 is arranged toextend away from first inflatable air bladder 21 through a portion 16 pof deformable elastic bed 16 as suggested in FIGS. 2, 5, and 6.

Second inflatable air bladder 22 is also formed to include a secondair-intake port 72 opening into second air chamber 50 and mating withsecond air-inlet conduit 46 as suggested in FIGS. 2, 3 a, and 4. Secondshells 52 a, 52 b mate with one another along a second shell interface53 and cooperate to form second air-intake port 72 therebetween assuggested in FIG. 2. Second outer shell 52 a of monolithic second sheet32 includes a continuous sealing edge 52 as interrupted by aport-forming edge 52 apf as shown in FIG. 4. Similarly, second innershell 52 b of monolithic first sheet 31 includes a continuous sealingedge 52 bs interrupted by a port-forming edge 52 bpf as shown in FIG. 4.When monolithic first sheet 31 is mated to monolithic second sheet 32,sealing edge 52 bs of second inner shell 52 b is sealingly coupled tosealing edge 52 as of second outer shell 52 a to form second air chamber50 and port-forming edge 52 apf of second outer shell 52 a is arrangedto lie in stationary confronting relation to port-forming edge 52 bpf ofsecond inner shell 52 b to form second air-intake port 72 therebetweenas suggested in FIGS. 3 a, 3 b, and 4.

Second air-inlet conduit 46 is arranged to extend into second air-intakeport 72 and is formed to include a passageway configured to providemeans for conducting pressurized air from a source 34 into second airchamber 50 to change the second inflatable air bladder 22 from adeflated state to an inflated state. In an illustrative embodiment,second air-inlet conduit 46 is arranged to extend away from secondinflatable air bladder 22 and through a portion 16 p of deformableelastic bed 16 parallel to first air-inlet conduit 44.

First web 41 of monolithic first sheet 31 includes a first plate 74 andan array of spaced-apart outwardly projecting domes 75 coupled to firstplate 74 as shown best in FIG. 4. In an illustrative embodiment, eachdome 75 included in first web 41 is larger than the domes 76 included infirst and second shells 51 b, 52 b as shown, for example, in FIG. 4.

Second web 42 of monolithic second sheet 32 includes a second plate 64arranged to lie in closely confronting relation to first plate 64 asshown in FIG. 2 and an array of spaced-apart inwardly projecting domes65 coupled to second plate 64 as shown best in FIG. 4. In anillustrative embodiment, each dome 65 included in second web 42 islarger than the domes 66 included in first and second shells 51 a, 52 aas shown, for example, in FIG. 4.

Each inwardly projecting dome 65 in second web 42 has a second base 68coupled to second plate 64 and a second tip 65T coupled to second base68 and arranged to lie in spaced-apart relation to second plate 64 assuggested in FIG. 4. Domes 65 can be formed to have any suitable shapeand frustoconical and frustopyramidal shapes are shown as an example inFIG. 4. Second tip 65T of dome 65 is arranged to contact first tip 75Tof a neighboring dome 75 to cause each companion pair of mating inwardlyand outwardly projecting domes 75, 65 to form a resilient deformablepost 82 included in deformable elastic bed 16 and arranged to extendbetween first and second plates 74, 64 as shown, for example, in FIGS. 2and 4.

As shown illustratively in FIG. 2, first inflatable air bladder 21 isconfigured to have a wedge shape having six sides. Second inflatable airbladder 22 is configured illustratively to have a U-shape having sixsides. As shown in FIG. 2, first and second inflatable air bladders 21,22 are arranged to be aligned with one another so that a wedge portion21 w of first inflatable air bladder 21 nests within an open portion 22u of second inflatable air bladder 22. During inflation of inflatableair bladders 21, 22, the interlocking arrangement of inflatable airbladders 21, 22 provides the passenger sitting in vehicle seat 10 with asensation that adjustable pneumatic passenger-support module 18 has acontinuous surface.

An occupant-support base 12 for a vehicle seat 10 illustrativelyincludes a cushion 14 as suggested in FIG. 1. Cushion 14 includes adeformable elastic bed 16 made of an elastomeric material and adapted tosupport a portion of an occupant P seated on cushion 14 and a firstinflatable air bladder 21 coupled to deformable elastic bed 16. Firstinflatable air bladder 21 is formed to include a first air chamber 48and a first air-intake port 71 opening into the first air chamber 48.

First inflatable air bladder 21 is made of the elastomeric material andconfigured to expand from a deflated state characterized by a firstvolume of air in first air chamber 48 to an inflated state characterizedby a relatively greater second volume of air in first air chamber 48 inresponse to admission of pressurized air 36 into first air chamber 48through the first air-intake port 71.

As an example, first inflatable air bladder 21 includes inner and outershells 51 a, 51 b made of the elastomeric material and arranged tocooperate to define first air chamber 48 therebetween. Inner shell 51 bincludes an inner plate 79 p and an outwardly projecting dome 76 coupledto inner plate 79 p and arranged to extend away from inner plate 79 pand into first air chamber 48 to support outer shell 51 a thereon in thedeflated state of first inflatable air bladder 21. Outer shell 51 a isarranged to separate from outwardly projecting dome 76 of inner shell 51b in the inflated state of first inflatable bladder 21, and outwardlyprojecting dome 76 of inner shell 51 b is configured to provide meansfor yieldably urging outer shell 51 a away from inner plate 79 p ofinner shell 51 b in the deflated state of first inflatable air bladder21 to block bottoming-out mating contact of outer shell 51 a on innerplate 79 p of inner shell 51 b during exposure of first inflatable airbladder 21 to an exterior load caused by occupant P seated on cushion14.

Occupant-support base 12 may also include a seat pan 24 that is arrangedto lie alongside cushion 14. Inner shell 51 b of first inflatable airbag 21 is retained in a fixed position on seat pan 24.

Cushion 14 includes a monolithic first sheet 31 made of the elastomericmaterial and configured to include inner shell 51 b and inner portionsof deformable elastic bed 16. Cushion 14 also includes a monolithicsecond sheet 32 made of the elastomeric material and configured toinclude outer shell 51 a and outer portions of deformable elastic bed16. Monolithic first sheet 31 is arranged to mate with monolithic secondsheet 32 to cause inner and outer shells 51 a, 51 b to mate in sealingrelation to form first air chamber 48 therebetween. Inner and outerportions of deformable elastic bed 16 mate to form a bladder-receivingcavity 61 a (e.g., shell basin) containing first inflatable air bladder21.

Seat pan 24 is arranged to lie alongside cushion 14. As an example,inner shell 51 b of first inflatable air bladder 21 and inner portion ofdeformable elastic bed 16 is retained in a fixed position on seat pan24. Monolithic second sheet 32 is arranged to lie in spaced-apartrelation to seat pan 24 to locate monolithic first sheet 31therebetween. Inner shell 51 b is arranged to lie on seat pan 24 tocause outwardly projecting domes 76 inner shell 21 to extend away fromseat pan 24 toward outer shell 51 a.

In one illustrative embodiment, outer shell 51 a includes an outer plate69 p and an inwardly projecting dome 66 coupled to outer plate 69 p toextend away from outer plate 69 p toward outwardly projecting dome 76 ofinner shell 51 b. Inwardly projecting dome 66 of outer shell 51 a isarranged to separate from outwardly projecting dome 76 of inner shell 51b in the inflated state of first inflatable bladder 21. Inwardly andoutwardly projecting domes 66, 76 cooperate to form a resilientdeformable post 84 inside first inflatable air bladder 21 to blockbottoming-out mating contact of outer plate 69 p of outer shell 51 a oninner plate 79 p of inner shell 51 b during exposure of first inflatableair bladder 21 to an exterior load caused by an occupant P seated on thecushion.

As shown in FIGS. 8-9 b, deformable elastic bed 16 is formed to includea left-wing bed section 91 along one side of cushion 14, a right-wingbed section 93 along an opposite side of cushion 14, and a backrest bedsection 92 located between and in angled relation to each left-wing andright-wing bed sections 91, 93. Left-wing and right-wing bed sections91, 93 are arranged to diverge in a direction extending away frombackrest bed section 92. First inflatable air bladder 21 is coupled tobackrest bed section 92 and is located in a bladder-receiving cavity 61a, 61 b formed in backrest bed section 92 to lie between left-wing andright-wing bed sections 91, 93.

Seat pan 24 is arranged to lie alongside 14 cushion and left-wing,right-wing, and backrest bed sections 91, 92, 93 of deformable elasticbed 16 are retained in fixed positions on seat pan 24. Inner shell 51 bof first inflatable air bladder 21 is retained in a fixed position onseat pan 24.

A vehicle seat 110, in accordance with another embodiment of the presentdisclosure, is illustrated in FIGS. 7-11. Vehicle seat 110 includes apair of inflatable air bladders 121, 122 that are located in left sidewing 186, backrest 188, and right side wing 190 included in cushion 114.

Vehicle seat 110 includes one occupant-support base 111 configured toprovide a seat bottom and another occupant-support base 112 configuredto provide a seat back arranged to extend upwardly from the seat bottomas shown in FIG. 7. In an illustrative embodiment, seat back 112includes a cushion 114 including a deformable elastic bed 116 and a pairof inflatable air bladders 121, 122. Deformable elastic bed 116 andinflatable air bladders 121, 122 are made from a suitable elastomericmaterial. As an example, the pair of inflatable air bladders 121, 122cooperate to form an adjustable pneumatic passenger-support module 118.

Deformable elastic bed 116 is configured to support a portion of anoccupant seated on cushion 114 of seat back 112. Inflatable air bladders121, 122 may be inflated using pressurized air stream 36 to expandoutwardly in outward directions 138 from a deflated state shown in FIGS.7, 8, and 10 to an inflated state shown in FIG. 11 to provide adjustabletorso support for a passenger seated in vehicle seat 110.

Seat back 112 includes a cushion cover 120, a cushion 114, and a seatpan 124 in an illustrative embodiment as shown, for example, in FIGS. 8and 9. A seat-pan support frame 26 can also be included in vehicle seat110 to support a seat pan included in seat back 112 or seat bottom 111as suggested in FIGS. 7 and 9. Cushion 114 is anchored to underlyingseat pan 124 using any suitable means and cushion cover 120 is coupledto cushion 114 and/or seat pan 124 using any suitable means and arrangedto cover deformable elastic bed 116 and inflatable air bladders 121, 122as suggested in FIGS. 7-9.

Cushion 114, as shown in FIG. 8, includes a left wing 186, a centralbackrest 188, and a right wing 190. First inflatable air bladder 121 isconfigured to lie in left wing 186 of cushion 114 and extend throughcentral backrest 188 of cushion 114 into right wing 190 of cushion 114.Second inflatable air bladder 122 is configured to lie in left wing 186and extend through central backrest 188 into right wing 190 of cushion114. As shown in FIG. 8, first and second inflatable air bladders 121,122 cooperate to provide an adjustable pneumatic passenger-supportmodule 118.

During use of adjustable pneumatic passenger-support module 118, a pumpcontroller 28 is activated by a vehicle passenger to actuate a manifold30 to direct a source of pressurized air, such as an air pump 34 coupledto an air source 29, to generate a pressurized air stream 36.Pressurized air stream 36 is conducted through a pair of hoses 140 a,140 b and then through a pair of associated air-inlet conduits 144, 146into air chambers 148, 150 formed in inflatable air bladders 121, 122 assuggested in FIG. 8. This causes inflatable air bladders 121, 122 toexpand outwardly in outward direction 138 to assume an inflated state assuggested in FIG. 11. It is within the scope of the present disclosureto use any suitable fluid pressure-management system to inflate anddeflate inflatable air bladders 121, 122.

First inflatable air bladder 121, as shown in FIG. 8, includes a firstbackrest section 155, a first left-wing section 157, and a firstright-wing section 159. First backrest section 155 is in fluidcommunication with first left-wing and right-wing sections 157, 159.Pressurized air stream 36 when admitted into first inflatable airbladder 121 moves freely among first backrest section 155, firstleft-wing section 157, and first right-wing section 159.

Second inflatable air bladder 122, as shown in FIG. 8, includes a secondbackrest section 156, a second left-wing section 158, and a secondright-wing section 160. Second backrest section 156 is in fluidcommunication with second left-wing and right-wing sections 158, 160.Pressurized air stream 36 when admitted into second inflatable airbladder 121 moves freely among second backrest section 156, secondleft-wing section 158, and second right-wing section 160.

Deformable elastic bed 116 of cushion 114 is formed to include aleft-wing bed section 191, a backrest bed section 192, and a right-wingbed section 193 as suggested in FIG. 8. First and second inflatable airbladders 121, 122 are arranged to lie in backrest bed section 192 andextend outwardly into left-wing bed section 191 and right-wing bedsection 193.

As shown in FIG. 9 a, backrest bed section 192 of deformable elastic bed116 includes a top portion 1921, an intermediate portion 1922, and abottom portion 1923. Intermediate portion 1922 is arranged tointerconnect top portion 1921 and bottom portion 1923. As illustrated inFIG. 9 a, first and second backrest sections 155, 156 of inflatable airbladders 121, 122 are positioned to lie in intermediate portion 1922 ofbackrest bed section 192.

Left-wing bed section 191 of deformable elastic bed 116 is formed toinclude a top portion 1911, an intermediate portion 1912, and a bottomportion 1913. Intermediate portion 1912 is arranged to interconnect topand bottom portions 1911, 1913. As illustrated in FIG. 9 a, first andsecond left-wing sections 157, 158 of associated first and secondinflatable air bladders 121, 122 are arranged to extend from first andsecond backrest sections 155, 156 into intermediate portion 1912 ofleft-wing bed section 191.

As shown in FIG. 9 a, right-wing bed section 193 of deformable elasticbed 116 is formed to include a top portion 1931, an intermediate portion1932, and a bottom portion 1933. Intermediate portion 1932 is arrangedto interconnect top portion 1931 and bottom portion 1933. First andsecond right-wing sections 159, 160 of first and second inflatable airbladders 121, 122 are arranged to extend from associated first andsecond backrest sections 155, 156 into intermediate portion 1932 ofright-wing bed section 193 as shown in FIG. 9 a.

A monolithic first sheet 131 and a monolithic second sheet 132 are matedtogether to form deformable elastic bed 116 and first and secondinflatable air bladders 121, 122 as suggested in FIGS. 9 a and 9 b.Illustratively, monolithic first and second sheets 131, 132 are made ofan elastomeric material.

Monolithic first sheet 131 includes a first web 141 that is configuredto form an inner portion of deformable elastic bed 116, a first innershell 151 b that is configured to form an inner portion of firstinflatable air bladder 121, and a second inner shell 152 b that isconfigured to form an inner portion of second inflatable air bladder 122as suggested in FIGS. 9 a and 10. Similarly, monolithic second sheet 132includes a second web 142 that is configured to form an outer portion ofdeformable elastic bed 116, a first outer shell 151 a that is configuredto form an outer portion of first inflatable air bladder 121, and asecond outer shell 152 a that is configured to form an outer portion ofsecond inflatable air bladder 122 as also suggested in FIG. 9 a.

As shown in FIGS. 10 and 11, first inner shell 151 b of first web 141includes a shell wall 179 w and a shell plate 179 p as shown in FIGS. 10and 11. Shell wall 179 w and shell plate 179 p cooperate to form a firstbackrest basin 191 b, a first left-wing basin 193 b, and a firstright-wing basin 195 b. First outer shell 151 a of second web 142 isformed to include a first backrest basin 191 a, a first left-wing basin193 a, and a first right-wing basin 195 a. First shells 151 a, 151 b aresealingly coupled together to cause first backrest basins 191 a, 191 bto communicate with one another to form a first backrest section 155, tocause first left-wing basins 193 a, 193 b to communicate with oneanother to form a first left-wing section 157, and to cause firstright-wing basins 195 a, 195 b to communicate with one another to form afirst right-wing section 159.

As shown in FIGS. 10 and 11, second shell 152 b of first web 141includes a shell wall 169 w and a shell plate 169 p as shown in FIGS. 10and 11. Shell wall 169 w and shell plate 169 p cooperate to form asecond backrest basin 192 a, a second left-wing basin 194 a, and asecond right-wing basin 196 a. Second shells 152 a, 152 b are sealinglycoupled together to cause second backrest basins 192 a, 192 b tocommunicate with one another to form a second backrest section 156, tocause second left-wing basins 194 a, 194 b to communicate with oneanother to form a second left-wing section 158, and to cause secondright-wing basins 196 a, 196 b to communicate with one another to form asecond right-wing section 160.

First inflatable air bladder 121 is also formed to include a firstair-intake port 171 opening into first backrest section 155 and matingwith first air-inlet conduit 144 as suggested in FIG. 9 a. First shells151 a, 151 b mate with one another along a first shell interface 154 andcooperate to form first air-intake port 171 therebetween. First shell151 b of first web 141 includes a continuous sealing edge 151 bsinterrupted by a port-forming edge 151 bpf as shown in FIG. 9 a.Similarly, first shell 151 a of second web 142 includes a continuoussealing edge 151 as interrupted by a port-forming edge 151 apf as shownin FIG. 9 a. When monolithic first sheet 131 is mated to monolithicsecond sheet 132, sealing edge 151 bs of first shell 151 b is sealinglycoupled to sealing edge 151 as of first shell 151 a to form first airchamber 148 and port-forming edge 151 bpf of first shell 151 b isarranged to lie in stationary confronting relation to port-forming edge151 apf of first shell 151 a to form first air-intake port 171therebetween as suggested in FIG. 9 a.

Second inflatable air bladder 122 is also formed to include a secondair-intake port 172 opening into second right-wing section 160 andmating with second air-inlet conduit 146 as suggested in FIG. 9 a.Second shells 152 a, 152 b mate with one another along a second shellinterface 161 and cooperate to form second air-intake port 172therebetween along second shell interface 161. Second shell 152 b offirst web 141 includes a continuous sealing edge 152 bs as interruptedby a port-forming edge 152 bpf as suggested in FIG. 9 a. Similarly,second shell 152 a of second web 142 includes a continuous sealing edge152 as interrupted by a port-forming edge 152 apf as shown in FIG. 4.When monolithic first sheet 131 is mated to monolithic second sheet 132,sealing edge 152 bs of second shell 152 b is sealingly coupled tosealing edge 152 as of second shell 152 a to form second air chamber 150and port-forming edge 152 bpf of second shell 152 b is arranged to liein stationary confronting relation to port-forming edge 152 apf ofsecond shell 152 a to form second air-intake port 172 therebetween.

As shown in FIG. 10, first inflatable air bladder 121 is in a deflatedstate with pressurized air stream 36 from manifold 30 being turned OFF.A passenger P (in phantom) is shown sitting in vehicle seat 110 with aportion of a passenger's torso being supported by first backrest section155 of first inflatable air bladder 121. Support is maintained withinfirst inflatable air bladder 121 by a series of outwardly projectingdomes 76 formed in first shell 151 b of first web 141 and by a series ofinwardly projecting domes 66 formed in first shell 151 a of second web142.

When first inflatable air bladder 121 is in the deflated stated, a firsttip 66T of dome 66 and a second tip 76T of dome 76 is arranged to lie inconfronting relation to one another as shown in FIG. 10. First tip 66Tis aligned above second tip 76T so that first tip 66T is supported bysecond tip 76T to cause a passenger resting on cushion 114 to besupported by the deflated inflatable air bladder 121. First tip 66T ofdome 66 is not coupled to second tip 76T of dome 76 so that when firstinflatable air bladder 121 is inflated, monolithic second sheet 132 ispermitted to move away from monolithic first sheet 131.

As shown in FIG. 11, first inflatable air bladder 121 is in the inflatedstated with pressurized air stream 36 from manifold 30 being turned ON.Second inflatable air bladder 122 functions illustratively in the samemanner as first inflatable air bladder 121 thus only first inflatableair bladder 121 will be discussed in detail. Passenger P (in phantom) isshown sitting in vehicle seat 110 with the passenger's torso beingsupported by first left-wing section 157, first backrest section 155,and first right-wing section 159. First left-wing section 157 isappended to first backrest section 155 by a first left-wing anchor 101interconnecting first monolithic sheet 131 and monolithic second sheet132 so that first inflatable air bladder 121 is restrained from movementin the area of first left-wing anchor 101.

Similar to first left-wing section 157, first right-wing section 159 isappended to first backrest section 155 by a first right-wing anchor 103interconnecting first monolithic sheet 131 and second monolithic sheet132 so that first inflatable air bladder 121 is restrained from movementin the area of first right-wing anchor. First right-wing anchor 103 andfirst left-wing anchor 101 cooperate to restrain first inflatable airbladder 121 so that the passenger's torso remains in contact with firstbackrest section 155 throughout inflation of first inflatable airbladder 121 as suggested in FIGS. 10 and 11. As shown in FIGS. 7, 8, and9, second inflatable air bladder 122 also includes second left-wing andright-wing anchors 102, 104 which function in the same way as firstleft-wing and right-wing anchors 101, 103 included in first inflatableair bladder 121.

Pressurized air stream 36 is communicated into first inflatable airbladder 121 through first air-inlet conduit 144. First air-inlet conduit144 is arranged to extend into first air-intake port 171 and formed toinclude a passageway configured to provide means for conductingpressurized air from a source 34 into first air chamber 148 to changethe first inflatable air bladder 121 from the deflated state shown inFIGS. 8 and 10 to the inflated state shown in FIG. 11. In anillustrative embodiment, second air-inlet conduit 146 is arranged toextend away from second inflatable air bladder 122 and through a portion116 p of deformable elastic bed 116 as suggested in FIGS. 8 and 9 a.

First web 141 of monolithic first sheet 131 includes a first plate 164and a series of spaced-apart upwardly projecting domes 76. Each upwardlyprojecting dome 76 has a first base 68 coupled to first plate 164 and afirst tip 76T coupled to first base 68 and arranged to lie inspaced-apart relation to first plate 64.

Second web 142 of monolithic second sheet 132 includes a second plate174 arranged to mate with first plate 164 as shown in FIG. 9 a and aseries of spaced-apart downwardly projecting domes 76 as shown best inFIG. 9 a. Each downwardly projecting dome 76 has a second base 78coupled to second plate 174 and a second tip 76T coupled to second base78 and arranged to lie in spaced-apart relation to second plate 174.Second tip 76T is coupled to first tip 66T to cause each companion pairof mating downwardly and upwardly projecting domes 66, 76 to form aresilient deformable post 82 included in deformable elastic bed 116 andarranged to extend between first and second plates 164, 174 as shown,for example, in FIG. 8.

Once monolithic first and second sheets 131, 132 are formed of anelastomeric material and mated (e.g., joined and welded) during acushion-manufacturing process, a first inflatable air bladder 121, asecond inflatable air bladder 122, and a deformable elastic bed 116 areformed. It is within the scope of this disclosure to locatebladder-receiving portion in an interior region of deformable elasticbed so that inflatable air bladders are surrounded on all sides byportions of deformable elastic bed. It is also within the scope of thisdisclosure to form a bladder-receiving portion along a perimeter edge ofa cushion so that the companion inflatable air bladders are surroundedpartly by portions of the companion deformable elastic bed.

As suggested in FIG. 7 and shown in FIG. 8, first and second inflatableair bladders 121, 122 are arranged to mate with one another in aninterlocking arrangement. The interlocking arrangement of inflatable airbladders 121, 122 provides a passenger sitting in vehicle seat 110 witha sensation that adjustable pneumatic passenger-support module 118 has acontinuous surface during four-way pneumatic adjustment ofpassenger-support module 118.

Cushion 14, 114 provides support to passengers when inflatable airbladders 21, 22 and 121, 122 are in the deflated state. Support isprovided by deformable elastic bed 16, 116. As an example, deformableelastic bed 16, 116 is formed to include a plurality of downwardlyextending domes 66 and upwardly extending domes 76 extending intoinflatable air bladders 21, 22 and 121, 122. As suggested in FIGS. 5 and10, downwardly extending domes 66 rest on upwardly extending domes 76 toprovide support to the passenger when inflatable air bladders 21, 22 and121, 122 are in the deflated state.

Deformable elastic bed 116 is formed to include a left-wing bed section191 along one side of cushion 114, a right-wing bed section 193 along anopposite side of cushion 114, and a backrest bed section 192 locatedbetween and in angled relation to each of left-wing and right-wing bedsections 191, 193. Left-wing and right-wing bed sections 191, 193 arearranged to diverge in a direction extending away from backrest bedsection 192. Inwardly and outwardly projecting domes 66, 76 are arrangedto lie in a central bladder-receiving cavity 139 formed in backrest bedsection 192.

In one illustrative embodiment, inner shell 151 b further includes anoutwardly projecting left-side dome 76 coupled to inner plate 179 p andis arranged to lie in a left bladder-receiving cavity 137 formed inleft-wing bed section 191 and arranged to extend away from inner plate179 p and into first air chamber 146 to support thereon a companionleft-side portion of the outer shell 151 a located in leftbladder-receiving cavity 137 in the deflated state of first inflatablebladder 121. Left-side portion of the outer shell 151 a is arranged toseparate from outwardly projecting left-side dome 76 of inner shell 151b in the inflated state of first air bladder 121. Outwardly projectingleft-side dome 76 is configured to provide means for yieldably urgingleft-side portion of the outer shell 151 a away from inner plate 179 pof inner shell 51 b to block bottoming-out mating contact of left-sideportion of outer shell 51 a and inner plate 79 p of inner shell 151 b inleft bladder-receiving cavity 137 during exposure of first inflatableair bladder 121 to an exterior load caused by an occupant P seated oncushion 114.

In another illustrative embodiment, outer shell 151 a further includesan inwardly projecting left-side dome 66 coupled to outer plate 169 pand arranged to lie in left bladder-receiving cavity 137 to extend awayfrom outer plate 169 p toward outwardly projecting left-side dome 76 ofinner shell 151 b. Inwardly projecting left-side dome 66 of outer shell151 a is arranged to separate from outwardly projecting left-side dome76 of inner shell 151 b in the inflated state of first inflatablebladder 121. Inwardly and outwardly projecting left-side domes 76, 66cooperate to form a resilient deformable post 84 inside left-wingbladder section 157 of first inflatable air bladder 121 located in leftbladder-receiving cavity 137 of deformable elastic bed 116 to blockbottoming-out mating contact of outer plate 169 p of outer shell 151 bon inner plate 179 p of inner shell 151 b during exposure of left-wingbladder section 157 of first inflatable air bladder 121 to an exteriorload caused by an occupant seated on cushion 114.

Inner shell 151 b further includes an outwardly projecting right-sidedome 76 coupled to inner plate 179 p and is arranged to lie in a rightbladder-receiving cavity 135 formed in right-wing bed section 193.Outwardly projecting right-side dome 76 is arranged to extend away frominner plate 179 p and into first air chamber 148 to support thereon acompanion right-side portion of outer shell 151 a located in rightbladder-receiving cavity 135 in the deflated state of first inflatablebladder 121. Right-side portion of the outer shell 151 a is arranged toseparate from outwardly projecting right-side dome 76 in the inflatedstate of first air bladder 121. Outwardly projecting right-side dome 76is configured to provide means for yieldably urging right-side portionof the shell 151 a away from inner plate 179 p of inner shell 151 b toblock bottoming-out mating contact of right-side portion 193 of outershell 151 a and inner plate 179 p of inner shell 151 b in rightbladder-receiving cavity 135 during exposure of first inflatable airbladder 121 to an exterior load caused by an occupant seated on cushion114.

Outer shell 151 a further includes an inwardly projecting right-sidedome 66 coupled to outer plate 169 p and arranged to lie in rightbladder-receiving cavity 135 and to extend away from outer plate 169 ptoward outwardly projecting right-side dome 76 of inner shell 151 b.Inwardly projecting right-side dome 66 of outer shell 151 a is arrangedto separate from outwardly projecting right-side dome 76 of inner shell151 b in the inflated state of first inflatable bladder 121. Inwardlyand outwardly projecting right-side domes 76, 66 cooperate to formresilient deformable post 84 inside a right-wing bladder section 159 offirst inflatable air bladder 121 located in right bladder-receivingcavity 135 of deformable elastic bed 116 to block bottoming-out matingcontact of outer plate 169 p of outer shell 151 a on inner plate 179 pof inner shell 151 b during exposure of right-wing bladder section 159of first inflatable air bladder 121 to an exterior load caused by anoccupant seated on cushion 114.

A vehicle seat 210 in accordance with another embodiment of the presentdisclosure is illustrated in FIGS. 12-16. Vehicle seat 210 includes apair of inflatable air bladders 221, 222 that are located in a backrest288 formed in cushion 214.

Vehicle seat 210 includes one occupant-support base 211 configured toprovide a seat bottom and another occupant-support base 212 configuredto provide a seat back arranged to extend upwardly from the seat bottomas shown in FIG. 12. In an illustrative embodiment, seat back 212includes a cushion 214 including a deformable elastic bed 216 and a pairof inflatable air bladders 221, 222 as suggested in FIGS. 13-14 a.Deformable elastic bed 216 and inflatable air bladders 221, 222 are madefrom a suitable elastomeric material. As an example, the pair ofinflatable air bladders 221, 222 cooperate to form an adjustablepneumatic passenger-support module 218.

Deformable elastic bed 216 is configured to support a portion of apassenger seated on cushion 214 in seat back 212. A plurality ofspaced-apart resilient deformable posts 82 are included in deformableelastic bed 216. Inflatable air bladders 221, 222 may be inflated usingpressurized air stream 36 to expand outwardly in outward directions 238from a deflated state shown in FIGS. 12-15 to an inflated state shown inFIG. 16 to provide adjustable lumbar support for a passenger seated invehicle seat 210.

During use of adjustable pneumatic passenger-support module 218, a pumpcontroller 28 is used by a passenger to actuate a manifold 30 to directa source of pressurized air, such as an air pump 34 coupled to an airsource 29, to generate a pressurized air stream 36. Pressurized airstream 36 is conducted through a pair of hoses 240 a, 240 b and thenthrough a pair of associated air-inlet conduits 244, 246 into airchambers 248, 250 formed in inflatable air bladders 221, 222 assuggested in FIG. 13. This causes inflatable air bladders 221, 222 toexpand outwardly in outward directions 238 to assume an inflated stateas suggested in FIG. 16. It is within the scope of the presentdisclosure to use any suitable fluid pressure management system toinflate and deflate inflatable air bladders 221, 222.

Cushion 214, as suggested in FIG. 12 and shown in FIG. 13, includes aleft wing 286, a central backrest 288, and a right wing 290. Firstinflatable air bladder 221 is positioned to lie in central backrest 288of cushion 214. Second inflatable air bladder 222 is positioned to liein central backrest 288 of cushion 214 below first inflatable airbladder 221. As shown in FIG. 13, first and second inflatable airbladders 221, 222 cooperate to provide an adjustable pneumaticpassenger-support module 218.

Deformable elastic bed 216 of cushion 214 is formed to include aleft-wing bed section 291, a backrest bed section 292, and a right-wingbed section 293 as suggested in FIG. 14. First and second inflatable airbladders 221, 222 are arranged to lie in backrest-bed section 292 ofdeformable elastic bed 216.

As shown in FIG. 14, backrest bed section 292 of deformable elastic bed216 includes a top portion 2921, an intermediate portion 2922, and abottom portion 2923. Intermediate portion 2922 is arranged tointerconnect top portion 2921 and bottom portion 2923. As illustrated inFIG. 14, first and second inflatable air bladders 221, 222 arepositioned to lie in intermediate portion 2922 of backrest bed section292.

Left-wing bed section 291 of deformable elastic bed 216 is formed toinclude a top portion 2911, an intermediate portion 2912, and a bottomportion 2913. Intermediate portion 2912 is arranged to interconnect topand bottom portions 2911, 2913. As shown in FIG. 14, right-wing bedsection 293 of deformable elastic bed 216 is formed to include a topportion 2931, an intermediate portion 2932, and a bottom portion 1933.Intermediate portion 2932 is arranged to interconnect top portion 1931and bottom portion 2933. As illustrated in FIG. 14, first and secondinflatable air bladders 121, 122 are arranged to lie betweenintermediate portion 2912 of left-wing bed section 291 and intermediateportion 2932 of right-wing bed section 293.

A monolithic first sheet 231 and a monolithic second sheet 232 are matedtogether to form deformable elastic bed 216. An outer sheet 233 andmonolithic second sheet 232 are mated together to form first and secondinflatable air bladders 221, 222 as suggested in FIGS. 14 and 14 a.Illustratively, monolithic first and second sheets 231, 232 andauxiliary sheet 233 are made of an elastomeric material.

Monolithic second sheet 232 includes a second web 242 that is configuredto form an outer portion of deformable elastic bed 216, a first innershell 251 a that is configured to form an inner portion of firstinflatable air bladder 221, and a second inner shell 252 a that isconfigured to form an inner portion of second inflatable air bladder 222as suggested in FIGS. 13 and 14 a. Outer sheet 233 forms an outerportion of second inflatable air bladder 222 as suggested in FIG. 14 a.

First inner shell 251 b of first web 241 includes a shell wall 279 w anda shell plate 279 p as shown in FIGS. 15 and 16. First outer shell 251 aof first second web 242 includes a shell wall 269 w and a shell plate279 p. First outer shell 25 a and auxiliary shell 233 are sealinglycoupled to one another to form first air chamber 248 therebetween assuggested in FIGS. 14 and 16. Second air chamber 250 is formed similarlyto first air chamber 248.

First inflatable air bladder 221 is also formed to include a firstair-intake port 271 opening into first air chamber 248 and mating withfirst air-inlet conduit 244 as suggested in FIGS. 14 a-16. Secondinflatable air bladder 222 is formed in a manner similar to firstinflatable air bladder 221 and only first inflatable air bladder 221will be described in detail. First inner shell 251 a and auxiliary shell251 c mate with one another along a first shell interface 254 andcooperate to form first air-intake port 271 therebetween. First innershell 251 a of second web 242 includes a continuous sealing edge 251 asinterrupted by a port-forming edge 251 apf as shown in FIG. 14 a.Similarly, auxiliary sheet 233 includes a continuous sealing edge 251 csinterrupted by a port-forming edge 251 cpf as shown in FIG. 14 a. Whenmonolithic second sheet 232 is mated to outer sheet 233, sealing edge251 as of first inner shell 251 a is sealingly coupled to sealing edge251 cs of first auxiliary sheet 233 to form first air chamber 248 andport-forming edge 251 apf of first inner shell 251 a is arranged to liein stationary confronting relation to port-forming edge 251 cpf of firstauxiliary sheet 233 to form first air-intake port 271 therebetween assuggested in FIGS. 14 a-16.

As shown in FIG. 15, first inflatable air bladder 221 is shown in adeflated state with the pressurized air stream 36 from manifold 30 beingturned OFF. A series of downwardly projecting domes 66 are formed infirst inner shell 251 a of second web 42. A series of upwardlyprojecting domes 76 are formed in a first web 241 of monolithic secondsheet 231. Domes 66 and 76 may be formed to have any suitable shape andfrustopyramidal shapes are shown as an example.

When first inflatable air bladder 221 is in the deflated stated, a firsttip 66T of dome 66 and a second tip 76T of dome 76 are arranged to liein confronting relation to one another. First tip 66T is aligned abovesecond tip 76T so that first tip 66T is supported by second tip 76T tocause a passenger resting on cushion 214 to be supported by deflatedinflatable air bladder 221. First tip 66T of dome 66 is coupled tosecond tip 76T of dome 76 so that when first inflatable air bladder 221is inflated, monolithic second sheet 232 is retained in positionrelative to monolithic first sheet 231 while outer sheet 233 moves awayfrom monolithic second sheet 232 toward an expansion perimeter 284 assuggested in FIG. 15 and shown in FIG. 16.

Once monolithic second sheet 32 and outer sheet 233 are formed of anelastomeric material and mated (e.g., joined and welded) during acushion-manufacturing process, a first inflatable air bladder 221, asecond inflatable air bladder 222 and a deformable elastic bed 216 areformed. It is within the scope of this disclosure to locatebladder-receiving portion in an interior region of deformable elasticbed so that inflatable air bladders are surrounded on all sides byportions of deformable elastic bed. It is also within the scope of thisdisclosure to form a bladder-receiving portion along a perimeter edge ofa cushion so that the companion inflatable air bladders are surroundedpartly by portions of the companion deformable elastic bed.

An occupant-support base 212 for a vehicle seat 210 includes a cushion214. Cushion 214 includes a deformable elastic bed 216 made of anelastomeric material and adapted to support a portion of an occupant Pseated on cushion 214, a first inflatable air bladder 221, firstair-intake port 271, and a bladder support 256. First inflatable airbladder 221 is coupled to deformable elastic bed 216 and formed toinclude a first air chamber 248. First air-intake port 271 opens intofirst air chamber 248. Bladder support 256 is coupled to deformableelastic bed 216 and is arranged to underlie first inflatable air bladder221. Bladder support 256 is defined by an inner shell 251 b including aninner plate 279 p and an outwardly projecting dome 76 coupled to innerplate 279 p and arranged to extend away from inner plate 279 p towardfirst inflatable air bladder 221.

First inflatable air bladder 221 is made of the elastomeric material andconfigured to expand from a deflated state characterized by a firstvolume of air in first air chamber 248 to an inflated statecharacterized by a relatively greater second volume of air in first airchamber 248 in response to admission of pressurized air 36 into firstair chamber 248 through first air-intake port 271. First inflatable airbladder 221 includes an outer shell 251 a and an auxiliary sheet 233made of elastomeric material and arranged to cooperate to define firstair chamber 248 therebetween. Outer shell 251 b includes an outer plate269 p and inwardly projecting dome 66 coupled to outer plate 269 p andarranged to extend away from outer plate 269 p and auxiliary sheet 233.Outer plate 269 p is arranged to support auxiliary sheet 233 thereon inthe deflated state of first inflatable air bladder 221.

Auxiliary sheet 233 is arranged to separate from outer plate 269 p inthe inflated state of first inflatable bladder 221 and outwardlyprojecting dome 76 of inner shell 251 b and inwardly projecting dome 66of outer shell 251 a cooperate to form resilient deformable post 84 toblock bottoming-out mating contact of outer plate 269 p of outer shell251 a on inner plate 279 p of inner shell 251 b during exposure of firstinflatable air bladder 221 to an exterior load caused by an occupantseated on seat cushion 214.

Seat pan 24 is arranged to lie alongside cushion 214 and inner shell 251b of first inflatable air bladder 221 is retained in a fixed position onseat pan 24. Cushion 214 includes a monolithic first sheet 231 and amonolithic second sheet 232 both made of the elastomeric material.Monolithic first sheet 231 is configured to include inner shell 251 band inner portions of the deformable elastic bed 216. Monolithic secondsheet 232 is configured to include the outer portions of the deformableelastic bed 216 and outer shell 251 a is arranged to mate in sealingrelation with the auxiliary sheet 233 to form first air chamber 248therebetween. As an example, outer portions of deformable elastic bed216 included in monolithic second sheet 232 cooperate to form abladder-receiving cavity 239 receiving at least a portion of firstinflatable air bladder 221 therein.

Seat pan 24 is arranged to lie alongside cushion 214 and inner shell 251b and inner portion of the deformable elastic bed 216 is retained in afixed position on seat pan 24. Monolithic second sheet 232 is arrangedto lie in spaced-apart relation to seat pan 24 to locate monolithicfirst sheet 231 therebetween.

Deformable elastic bed 216 is formed to include a left-wing bed section291 along one side of cushion 214, a right-wing bed section 293 along anopposite side of cushion 214, and a backrest bed section 292 locatedbetween and in angled relation to each of left-wing and right-wing bedsections 291, 293. First inflatable air bladder 221 is coupled tobackrest bed section 292 and is arranged to extend into left-wing andright-wing bed sections 291, 293 and are arranged to diverge in adirection extending away from backrest bed section 292.Bladder-receiving cavity 239 is formed in backrest bed section 292 tolie between left-wing and right-wing bed sections 291, 293. Seat pan 24is arranged to lie alongside cushion 214. Left-wing, right-wing, andbackrest bed sections 291, 292, 293 of deformable elastic bed 216 areretained in fixed positions on seat pan 24 and inner shell 251 b ofbladder support 256 is retained in a fixed position on seat pan 24.

A vehicle seat 310, in accordance with another embodiment of the presentdisclosure, is illustrated in FIGS. 17-21. Vehicle seat 310 includes apair of inflatable air bladders 321, 322 that are located in left sidewing 386, backrest 388, and right side wing 390 included in cushion 314.

Vehicle seat 310 includes one occupant-support base 311 configured toprovide a seat bottom and another occupant-support base 312 configuredto provide a seat back arranged to extend upwardly from the seat bottomas shown in FIG. 17. In an illustrative embodiment, seat back 312includes a cushion 314 including a deformable elastic bed 316 and a pairof inflatable air bladders 321, 322 as suggested in FIGS. 19 a and 19 b.Deformable elastic bed 316 and inflatable air bladders 321, 322 are madefrom a suitable elastomeric material. As an example, the pair ofinflatable air bladders 321, 322 cooperate to form an adjustablepneumatic passenger-support module 318.

Deformable elastic bed 316 is configured to support a portion of anoccupant seated on cushion 314 in seat back 312. A plurality ofspaced-apart resilient deformable posts 82 are included in deformableelastic bed 316. Inflatable air bladders 321, 322 may be inflated usingpressurized air stream 36 to expand outwardly in outward directions 338from a deflated state shown in FIGS. 17, 18, and 20 to an inflated stateshown in FIG. 21 to provide adjustable torso support for a passengerseated in vehicle seat 310.

Seat back 312 includes a cushion cover 120, cushion 314, and a seat pan124 in an illustrative embodiment as shown, for example, in FIGS. 18 and19. A seat-pan support frame 26 can also be included in vehicle seat 310to support a seat pan 124 included in seat back 312 or seat bottom 311as suggested in FIG. 19. Cushion 314 is anchored to underlying seat pan124 using any suitable means and cushion cover 120 is coupled to cushion314 and/or seat pan 124 using any suitable means and arranged to coverdeformable elastic bed 316 and inflatable air bladders 321, 322 assuggested in FIGS. 17-19.

Cushion 314, as shown in FIG. 18, includes a left wing 386, a centralbackrest 388, and a right wing 390. First inflatable air bladder 321 isconfigured to lie in left wing 386 of cushion 314 and extend throughcentral backrest 388 of cushion 314 into right wing 390 of cushion 314.Second inflatable air bladder 322 is configured to lie in left wing 386and extend through central backrest 388 into right wing 390 of cushion314. As shown in FIG. 18, first and second inflatable air bladders 321,322 cooperate to provide an adjustable pneumatic passenger-supportmodule 318.

During use of adjustable pneumatic passenger-support module 318, a pumpcontroller 28 is activated by a vehicle passenger to actuate a manifold30 to direct a source of pressurized air, such as an air pump 34 coupledto an air source 29, to generate a pressurized air stream 36.Pressurized air stream 36 is conducted through a pair of hoses 340 a,340 b and then through a pair of associated air-inlet conduits 344, 346into air chambers 348, 350 formed in inflatable air bladders 321, 322 assuggested in FIG. 18. This causes inflatable air bladders 321, 322 toexpand outwardly in outward direction 338 to assume an inflated state assuggested in FIG. 21. It is within the scope of the present disclosureto use any suitable fluid pressure management system to inflate anddeflate inflatable air bladders 321, 322.

First inflatable air bladder 321, as shown in FIG. 18, includes a firstbackrest section 355, a first left-wing section 357, and a firstright-wing section 359. First backrest section 355 is in fluidcommunication with first left-wing and right-wing sections 357, 359.Pressurized air stream 36 when admitted into first inflatable airbladder 321 moves freely among first backrest section 355, firstleft-wing section 357, and first right-wing section 359.

Second inflatable air bladder 322, as shown in FIG. 18, includes asecond backrest section 356, a second left-wing section 358, and asecond right-wing section 360. Second backrest section 356 is in fluidcommunication with second left-wing and right-wing sections 358, 360.Pressurized air stream 36 when admitted into second inflatable airbladder 321 moves freely among second backrest section 356, secondleft-wing section 358, and second right-wing section 360.

Deformable elastic bed 316 of cushion 314 is formed to include aleft-wing bed section 391, a backrest bed section 392, and a right-wingbed section 393 as suggested in FIG. 18. First and second inflatable airbladders 321, 322 are arranged to lie above backrest-bed section 392 andextend outwardly above left-wing bed section 391 and right-wing bedsection 393.

As shown in FIG. 19 b, backrest bed section 392 of deformable elasticbed 316 includes a top portion 3921, an intermediate portion 3922, and abottom portion 3923. Intermediate portion 3922 is arranged tointerconnect top portion 3921 and bottom portion 3923. As illustrated inFIG. 19 a, first and second backrest sections 355, 356 of inflatable airbladders 321, 322 are positioned to lie above intermediate portion 3922of backrest bed section 316.

Left-wing bed section 391 of deformable elastic bed 316 is formed toinclude a top portion 3911, an intermediate portion 3912, and a bottomportion 3913. Intermediate portion 3912 is arranged to interconnect topand bottom portions 3911, 1913. As illustrated in FIG. 19 b, first andsecond left-wing sections 357, 358 of associated first and secondinflatable air bladders 321, 322 are arranged to extend from first andsecond backrest sections 355, 356 above intermediate portion 3912 ofleft-wing bed section 391.

As shown in FIG. 19 b, right-wing bed section 393 of deformable elasticbed 316 is formed to include a top portion 3931, an intermediate portion3932, and a bottom portion 3933. Intermediate portion 3932 is arrangedto interconnect top portion 3931 and bottom portion 3933. First andsecond right-wing sections 359, 360 of first and second inflatable airbladders 321, 322 are arranged to extend from associated first andsecond backrest sections 355, 356 above intermediate portion 3932 ofright-wing bed section 393 as shown in FIG. 19 b.

A monolithic first sheet 331 and a monolithic second sheet 332 are matedtogether to form deformable elastic bed 316. An outer sheet 333 andmonolithic second sheet 332 are mated together to form first and secondinflatable air bladders 321, 322 as suggested in FIGS. 19 a and 19 b.Illustratively, monolithic first and second sheets 331, 332 and outersheet 333 are made of an elastomeric material.

Monolithic second sheet 332 includes a second web 342 that is configuredto form an outer portion of deformable elastic bed 316, a first innershell 351 a that is configured to form an inner portion of firstinflatable air bladder 321, and a second inner shell 352 a that isconfigured to form an inner portion of second inflatable air bladder 322as suggested in FIGS. 19 b and 20. Outer sheet 333 includes a firstauxiliary shell 351 c that is configured to form an outer portion offirst inflatable air bladder 321 and a second auxiliary shell 352 c thatis configured to form an outer portion of second inflatable air bladder322 as suggested in FIG. 19 a.

First inner shell 351 b of first web 342 includes a shell wall 379 w anda shell plate 379 p as shown in FIGS. 20 and 21. First outer shell 351 aof second web 342 includes a shell wall 369 w and a shell plate 369 p.Auxiliary sheet 433 and first outer shell 351 a are sealingly coupledtogether to form air chamber 348 therebetween. Second air chamber 350 isalso formed in a manner similar to air chamber 348. A first air-intakeport 371 is formed in air chamber 348 that opens into first backrestsection 355 as suggested in FIGS. 19 a and 19 b.

As an example, second inner shell 352 a of second web 342 is formed toinclude a second backrest basin 392 a, a second left-wing basin 394 a,and a second right-wing basin 396 a. Second auxiliary shell 352 c ofouter sheet 333 is formed to include a second backrest basin 392 c, asecond left-wing basin 394 c, and a second right-wing basin 396 c.Second shells 352 a, 352 c are sealingly coupled together to causesecond backrest basins 392 a, 392 c to communicate with one another toform a second backrest section 356, to cause second left-wing basins 394a, 394 c to communicate with one another to form a second left-wingsection 358, and to cause second right-wing basins 396 a, 396 c tocommunicate with one another to form a second right-wing section 360.Second inflatable air bladder 322 is also formed to include a secondair-intake port 372 opening into second right-wing section 360 assuggested in FIGS. 19 a and 19 b.

Second inflatable air bladder 322 is formed in a manner similar to firstinflatable air bladder 321 and only construction of first inflatable airbladder 321 will be described in detail. First shells 351 a, 351 c matewith one another along a first shell interface 354 and cooperate to formfirst air-intake port 371 therebetween. First inner shell 351 a ofsecond web 342 includes a continuous sealing edge 351 as interrupted bya port-forming edge 351 apf as shown in FIG. 19 a. Similarly, firstauxiliary shell 351 c includes a continuous sealing edge 351 csinterrupted by a port-forming edge 351 cpf as shown in FIG. 19 a. Whenmonolithic second sheet 332 is mated to outer sheet 333, sealing edge351 as of first inner shell 351 a is sealingly coupled to sealing edge351 cs of first auxiliary shell 351 c to form first air chamber 348 andport-forming edge 351 apf of first inner shell 351 a is arranged to liein stationary confronting relation to port-forming edge 351 cpf of firstauxiliary shell 351 c to form first air-intake port 371 therebetween assuggested in FIGS. 19-21.

As shown in FIG. 21, first inflatable air bladder 321 is in the inflatedstated as a result of pressurized air stream 36 from manifold 30 beingturned ON. Second inflatable air bladder 322 functions illustratively inthe same manner as first inflatable air bladder 321, thus only firstinflatable air bladder 321 will be discussed in detail. Passenger P (inphantom) is shown sitting in vehicle seat 310 with the passenger's torsobeing supported by first left-wing section 357, first backrest section355, and first right-wing section 359. First left-wing section 357 isappended to first backrest section 355 by a first left-wing anchor 301interconnecting first monolithic sheet 331 and auxiliary sheet 333 sothat first inflatable air bladder 321 is restrained from movement in thearea of first left-wing anchor 301.

First right-wing section 359 is appended to first backrest section 355by a first right-wing anchor 303 interconnecting first monolithic sheet331 and auxiliary sheet 333 so that first inflatable air bladder 321 isrestrained from movement in the area of the first right-wing anchor 303.First right-wing and left-wing anchors 301, 303 cooperate to restrainfirst inflatable air bladder 321 so that the passenger's torso remainsin contact with first backrest section 355 throughout inflation of thefirst inflatable air bladder 321 as suggested in FIGS. 20 and 21. Asshown in FIGS. 17, 18, and 19 a, second inflatable air bladder 322 alsoincludes second left-wing and right-wing anchors 302, 304 which functionin the same way as first left-wing and right-wing anchors 301, 303included in first inflatable air bladder 321.

Deformable elastic bed 316 is formed to include a left-wing bed section391 along one side of cushion 314, a right-wing bed section 393 along anopposite side of cushion 314, and a backrest bed section 392 locatedbetween and in angled relation to each of left-wing and right-wing bedsections 391, 393. Left-wing and right-wing bed sections 391, 393 arearranged to diverge in a direction extending away from backrest bedsection 392. Inner shell 351 b further includes outwardly projectingleft-side dome 76 coupled to inner plate 379 p. Outer shell 351 afurther includes inwardly projecting left-side dome 66 coupled to outerplate 369 p and arranged to lie in a left bladder-receiving cavity 337formed in left-wing bed section 391 to extend away from outer plate 351a toward outwardly projecting left-side dome 76 of inner shell 351 b.Inwardly and outwardly projecting left-side domes 66, 76 cooperate toform resilient deformable post 84 associated with left-wing bed section391 of the deformable elastic bed to block bottoming-out mating contactof outer plate 351 a of outer shell 351 a on inner plate 351 b of innershell 351 b during exposure of left-wing bladder section of firstinflatable air bladder 321 to an exterior load caused by an occupantseated on cushion 314. Auxiliary sheet 333 and left-side portion ofouter shell 351 a includes inwardly projecting left-side dome 66cooperate to form therebetween a left-side subchamber of the first airchamber 348L.

Inner shell 351 b further includes outwardly projecting right-side dome76 coupled to inner plate 379 p. Outer shell 351 a further includesinwardly projecting right-side dome 66 coupled to outer plate 369 p andis arranged to lie in a right bladder-receiving cavity 335 formed inright-wing bed section 393 to extend away from outer plate 369 p towardoutwardly projecting right-side dome 76 of inner shell 351 b. Inwardlyand outwardly projecting right-side domes 66, 76 cooperate to formresilient deformable post 84 associated with right-wing section 393 ofdeformable elastic bed 316 to block bottoming-out mating contact ofouter plate 369 p of outer shell 351 a on inner plate 379 of inner shell351 b during exposure of right-wing bladder section of first inflatableair bladder 321 to an exterior load caused by an occupant seated oncushion 314. Auxiliary sheet 333 and right-side portion of outer shell351 a includes inwardly projecting right-side dome 66 cooperate to formtherebetween right-side subchamber 348R of first air chamber 348associated with right-wing bed section 393 of deformable elastic bed316. Auxiliary sheet 333 and central portion of the outer shellincluding inwardly projecting dome 66 cooperate to form therebetween acentral subchamber 248C of first air chamber 248 associated with centralbackrest bed section 392. Central subchamber 248C is arranged tointerconnect and provide fluid communication between left-side andright-side subchambers 348L, 348R of first air chamber 348.

A vehicle seat 410, in accordance with another embodiment of the presentdisclosure, is illustrated in FIGS. 22-31. Vehicle seat 410 includesseat bottom 11 and a seat back 412 as shown in FIG. 22. In anillustrative embodiment, seat back 412 includes a cushion 414 includinga deformable elastic bed 416 and a pair of rectangle-shaped lumbarbladders 421, 422, a pair of half-moon shaped inflatable bolsterbladders 423, 424, and several inflatable massage bladders 430B assuggested in FIG. 22 and shown in FIGS. 23, 24, and 27-29. Deformableelastic bed 416 is configured to support a portion of a passenger seatedon cushion 414 of seat back 412 when the inflatable air bladders are notinflated. Each inflatable bladder 421, 422, 423, 424, 430 may beinflated separately by pressurized air coming from a manifold 429 assuggested in FIGS. 24 and 26 to provide adjustable lumbar support andmassage to a passenger seated in vehicle seat 410.

Deformable elastic bed 416 is configured to support a portion of anoccupant seated on cushion 414 in seat back 412. A plurality ofspaced-apart resilient deformable posts 482 are included in deformableelastic bed 416 as shown in FIGS. 23, 24, and 28. Each inflatablebladder 421, 422, 423, 424, 430 may be inflated individually usingpressurized air stream 36 to expand outwardly in outward direction 446from a deflated state to an inflated state. As shown in FIG. 23, allinflatable bladders 421, 422, 423, 424, 430 are in the deflated state.As shown, for example, in FIG. 24, upper rectangle-shaped lumber bladder421, right moon-shaped bolster bladder 423, and a third massage bladder433B are in the inflated state to provide adjustable torso support andmassage for a passenger seated in vehicle seat 410.

Seat back 412 includes a cushion cover 420, cushion 414, and a seat pan425 in an illustrative embodiment as shown, for example, in FIG. 27. Aseat-pan support frame 26 can also be included in vehicle seat 410 tosupport a seat pan 425 included in seat back 412 or seat bottom 11 assuggested in FIG. 27. Cushion 414 is anchored to underlying seat pan 425using any suitable means and cushion cover 420 is coupled to cushion 414and/or seat pan 425 using any suitable means and is arranged to coverdeformable elastic bed 416 and inflatable bladders 421, 422, 423, 424,430 as suggested in FIGS. 22 and 27.

Cushion 414, as shown in FIG. 23, includes a left wing 486, a centralbackrest 488, and a right wing 490. First bolster bladder 423 isarranged to lie in right wing 490 of cushion 414. Second bolster bladder424 is arranged to lie in left wing 486. First and second lumbarbladders 421, 422 are arranged to lie between first and second bolsterbladders 423, 424 in central backrest 488. Massage bladders 430B arealso arranged to lie in central backrest 488. Inflatable bladders 421,422, 423, 424, 430B cooperate to provide an adjustable pneumaticpassenger-support module 418.

Central backrest 488 includes an upper portion 488U and a lower portion488L as shown in FIGS. 23 and 24. First and second bolster bladders 421,422 are arranged to lie in lower portion 488L. Massage bladders 430Billustratively are ten separate bladders 431B, 432B, 433B, 434B, 435B,436B, 437B, 438B, 439B, and 440B. As shown in FIGS. 23 and 24, first,second, third, and fourth massage bladders 431B, 432B, 433B, 434B arealso arranged to lie in lower portion 488L of central backrest 488.Remaining fifth, sixth, seventh, eighth, ninth, and tenth inflatablemassage bladders 435B, 436B, 437B, 438B, 439B, 440B are arranged to liein upper portion 488U. As shown in FIG. 23, inflatable massage bladders431B, 432B, 433B, 434B, 435B, 436B, 437B, 438B, 439B, 440B are arrangedinto to columns of spaced-apart massage bladders spanning a length ofcushion 414.

During use of adjustable pneumatic passenger-support module 418, a pumpcontroller 428 is activated by a vehicle passenger to actuate a manifold429 to direct a source of pressurized air, such as an air pump 427coupled to an air source 29, to generate a pressurized air stream 36.Pressurized air stream 36 is conducted through a series of hoses 430Hinto associated air chambers formed in inflatable bladders 421, 422,423, 424, 430 as suggested in FIGS. 22-24. It is within the scope of thepresent disclosure to use any suitable fluid pressure management systemto inflate and deflate inflatable air bladders.

Inflatable bladders 421, 422, 423, 424 and deformable elastic bed 416are formed when a monolithic first sheet 441 and a monolithic secondsheet 442 are mated together as shown in FIGS. 25, 26, and 28.Illustratively, monolithic first and second sheets 441, 442 are made ofan elastomeric material. As suggested in FIGS. 27 and 28, monolithicfirst sheet 441 is arranged to lie in confronting relation with seat pan425. Monolithic second sheet 442 is arranged to locate monolithic firstsheet 441 between monolithic second sheet 442 and seat pan 425.

Monolithic first sheet 441 includes a first web 451 that is configuredto form an outer portion of deformable elastic bed 416, a first innerlumbar shell 461A that is configured to form an inner portion of firstlumbar bladder 421, a second inner lumbar shell 462A that is configuredto form an inner portion of second lumbar bladder 422, a first innerbolster shell 463A that is configured to form an inner portion of firstbolster bladder 423, and a second inner bolster shell 464A that isconfigured to form an inner portion of second bolster bladder 424 assuggested in FIG. 28. Monolithic second sheet 442 includes a second web452 that is configured to form an outer portion of deformable elasticbed 416, a first outer lumbar shell 461B that is configured to form anouter portion of first lumbar bladder 421, a second outer lumbar shell462B that is configured to form an outer portion of second lumbarbladder 422, a first outer bolster shell 463B that is configured to forman outer portion of first bolster bladder 423, and a second outerbolster shell 464B that is configured to form an outer portion of secondbolster bladder 424 as suggested in FIG. 28.

As suggested in FIGS. 25, 26, and 28, first lumbar shells 461A, 461B arecoupled together sealingly to establish first lumbar bladder 421. Secondlumbar shells 462A, 462B are coupled together sealing to establishsecond lumbar bladder 422. First bolster shells 463A, 463B are coupledtogether sealingly to establish first bolster bladder 423. Secondbolster shells 464A, 464B are coupled together sealingly to establishsecond bolster bladder 424.

First lumbar bladder 421 is formed in a manner similar to first andsecond bolster bladders 423, 424 and second lumbar bladder 422 and onlyconstruction of first lumbar bladder 421 will be discussed in detail.First lumbar shells 461A, 461B mate with one another along a firstlumbar-shell interface 454. An air-intake port (not shown) may be formedin first lumbar-shell interface 454. First inner lumbar shell 461A offirst web 451 includes a continuous sealing edge 461AS that may beinterrupted by a port-forming edge as shown in FIG. 28. Similarly, firstouter lumbar shell 461B includes a continuous sealing edge 461BS thatmay be interrupted by a port-forming edge. When monolithic first sheet441 is mated with monolithic second sheet 442, sealing edge 461AS offirst inner lumbar shell 461A is coupled sealingly to sealing edge 461BSof first outer lumbar shell 461B to form a first lumbar air chamber 468.In one embodiment, an air-intake port may be formed by confrontingport-forming edges that may be included in each lumbar shell 461A, 462B.In another embodiment, an air-intake port may be established by formingan aperture in one of the shells.

As shown in FIGS. 23 and 25, all the inflatable bladders 421, 422, 423,424, 430 are in the deflated state with pressurized air stream 36 frommanifold 429 being turned OFF to each bladder. While in the deflatedstate, a passenger sitting in vehicle seat 410 is supported by a seriesof free-standing domes 46D2, 47D2 that are formed in inflatable bladders421, 422, 423, 424, 430. As shown, for example, in FIG. 25, a first dome47D2 is formed in first outer lumbar shell 461B of second monolithicsheet 442 and is arranged to extend away from first monolithic sheet 441to support a passenger sitting in vehicle seat 410 when first inflatablelumbar bladder 421 in the deflated state. As another example, a seconddome 46D2 is formed in first bolster shell 463A of first monolithicsheet 441 and is arranged to extend away from seat pan 425 into firstbolster air chamber 473 to support a passenger when first inflatablebolster bladder 423 in the deflated state.

When the pneumatic passenger-support module 418 is in the deflatedstate, a passenger resting on cushion 414 is supported by deformableelastic bed 416. As shown in FIG. 28, deformable elastic bed 416 isformed as the result of mating a monolithic first sheet 441 and amonolithic second sheet 442 together. Monolithic first sheet 441 isformed to include several upwardly extending free-standing domes 46D1,46D2. As an example, domes 46D2 are formed in a lower portion ofmonolithic first sheet 441 as part of shells 461A, 462A, 463A, 464A andhave a first height 4H1 which is generally the thickness of thecushions. Domes 46D1 are formed in an upper portion of monolithic firstsheet 441 and have a second height 4H2. Second height 4H2 is less thanfirst height 4H1, and as an example, is about half the first height 4H1.Domes 46D1 are configured to mate with downwardly extending domes 47D1formed in second monolithic sheet 442.

Monolithic second sheet 442 is formed to include several downwardlyextending free-standing domes 47D1 (shown in FIG. 28) and severalupwardly extending free-standing domes 47D2 (shown in FIGS. 25, 26, and28). In the illustrative embodiment shown in FIGS. 25 and 26, upwardlyextending domes 47D2 are formed as part of lumbar shells 461B, 462B andare configured extend generally the thickness of cushion 414 and havefirst height. Downwardly extending free-standing domes 47D1, incomparison, are generally included in second web 452 and are arranged toalign and mate with upwardly extending domes 46D3 of second monolithicsheet 442 to establish spaced-apart resilient deformable posts 482 assuggested in FIG. 28. Resilient deformable posts 482 generally span thethickness of cushion 414 and have a third height which may be equal tofirst height 4H1 or slightly greater than first height 4H1.

An example of use, as shown in FIGS. 24 and 26, first inflatable bolsterand lumbar bladders 421, 423 and third inflatable massage bladder 433Bare in the inflated state as a result of pressurized air stream 36 frommanifold 30 being turned ON to bladders 421, 423, and 433. Secondinflatable bolster bladder 424 functions illustratively in the samemanner as first inflatable bolster bladder 423, and thus, only firstinflatable bolster bladder 423 will be discussed in detail. Secondinflatable lumbar bladder 422 operates illustratively in the same manneras first inflatable lumbar bladder 421, and thus, only first inflatablelumbar bladder 421 will be discussed in detail. Finally, the otherinflatable massage bladders 431B, 432B, 434B, 435B, 436B, 437B, 438B,439B, 440B operate in illustratively in the same manner as thirdinflatable massage bladder 433B, and thus, only third inflatable massagebladder 433B will be discussed in detail.

First inflatable bolster bladder 423 is formed as a result of couplingfirst bolster shell 463A of first monolithic sheet 441 to first bolstershell 463B of second monolithic shell. As shown in FIG. 25, firstbolster shell 463B is arranged to lie in confronting relation withsecond dome 46D2 formed in first bolster shell 463A when firstinflatable bolster bladder 423 is in the deflated position. As a resultof admitting pressurized air into first bolster chamber 473, firstbolster shell 463B moves away from first bolster shell 463A as shown inFIG. 25.

First inflatable lumbar bladder 421 is formed as a result of couplingfirst inner lumbar shell 461A of first monolithic sheet 441 to firstlumbar inner shell 461A of second monolithic shell. As shown in FIG. 25,first inner lumbar shell 461A is arranged to lie confronting relationwith first outer lumbar shell 461B. First dome 47D2 is formed in firstouter lumbar shell 461B to provide support to passengers when firstinflatable lumbar bladder 421 is in the deflated state. Afterpressurized air 36 has been admitted into first lumbar air chamber 471,first outer lumbar shell 461B moves away from first inner lumbar shell461A to cause the first outer lumbar shell 461B to establish anexpansion perimeter 461P as shown in FIG. 26. As illustrated in FIGS. 25and 26, first outer lumbar shell 461B is formed to include amassage-bladder cavity 444. Bladder-receiving cavity 444 is defined byupwardly extending dome 47D2 and a downwardly extending moat 4M1arranged to surround dome 47D2. As an example, third massage unit 433 isarranged to lie in bladder-receiving cavity 444 as suggested in FIGS.23-26, 28, and 29.

As shown in FIG. 29, massage units 430 are each arranged to lie inindividual bladder-receiving cavities 444 formed in monolithic secondsheet 442. First and second massage units 431, 432 are arranged to liein bladder-receiving cavities 444 formed in second outer lumbar shell462B of second monolithic sheet 442. As an example, first and secondmassage units 431, 432 are arranged to lie in bladder-receiving cavities444 formed in second outer lumbar shell 462B of second lumbar bladder422. Similarly, second and third massage units 433, 434 are arranged tolie in bladder-receiving cavities 444 formed in first outer lumbar shell461B of first lumber bladder 421. Fifth, sixth, seventh, eighth, ninth,and tenth inflatable massage units 435, 436, 437, 438, 439 and 440 arearranged to lie in bladder-receiving cavities 444 formed in second web452 of second monolithic sheet 442.

Third inflatable massage bladder 433B operates in illustratively thesame manner as other inflatable massage bladders 431B, 432B, 434B, 435B,436B, 437B, 438B, 439B, 440B, and thus, only third inflatable massagebladder 433B will be discussed in detail. Third inflatable massagebladder 433B is formed in response to joining a third massage unit 433to first outer lumbar shell 461B of second monolithic sheet 442. Thirdmassage unit 443 illustratively includes a first expansion layer 4331, asecond expansion layer 4332, and a third expansion layer 4333 as shownin FIGS. 25, 26, 30 and 31. Third expansion layer 4333 is coupled to anouter surface of first outer lumbar shell 461B to establish a firstmassage chamber 456 therebetween as shown in FIG. 26. First expansionlayer 4331 is coupled to second expansion layer 4332 to establish asecond massage chamber 458 therebetween as illustrated, for example, inFIG. 26. Second expansion layer 4332 is coupled to third expansion layer4333 to provide a passageway 478 that allows pressurized air 36 tocommunicate between the first and second massage chambers 456, 458 asshown in FIG. 26.

As shown in FIGS. 30 and 31, third expansion layer 4333 includes aflange portion 4333F and a dome portion 4333D. Dome portion 4333D isappended to the flange portion 4333F and arranged to extend outwardlyaway from second monolithic sheet 442. Dome portion 4333D is sized sothat dome 47D2 is receive therein when third inflatable massage unit 433is coupled to first outer lumbar shell 461B. Moat 4M1 is sized toreceive flange portion 4333F therein and dome portion 4333D of thirdexpansion layer 4333 is coupled to moat 4M1 by flange portion 4333F asshown in FIGS. 25 and 26. As illustrated in FIG. 25, dome portion 4333Dincludes a perimeter wall 494 and a ceiling 496 extending between theperimeter wall 494. A first aperture 475 is formed in ceiling 496 and isconfigured to provide a portion of passageway 478. A second aperture 476is formed in perimeter wall 494 that is coupled sealingly to hose 433Hso that pressurized air 36 may be admitted to third inflatable massagerbladder 433B.

Second expansion layer 4332 includes a perimeter 4332P and an aperture474 as shown in FIG. 31. Aperture 474 is formed to open into secondmassage chamber 458 and is aligned with first aperture 475 of thirdexpansion layer 4333 to provide passageway 478. First expansion layer4331 includes a perimeter 4331P that is coupled sealingly to perimeter4332P of second expansion layer 4332 so that second massage chamber 458is formed between first and second expansion layer 4331, 3332.Passageway 478 allows pressurized air 36 to move freely between firstand second massage chambers 456, 458 as shown in FIG. 26. Firstexpansion layer 4331 is also formed to include a pattern of surfacefeatures 498 which are illustratively three rectangle-shaped raisedconcentric rings.

Third inflatable massage bladder 433B, as shown in FIG. 25, is in adeflated state as a result of pressurized air stream 36 from manifold 30being turned OFF to massage bladder 433B. As a result, ceiling 496 ofthird expansion layer 4333 is arranged to lie in confronting relation onfirst upwardly extending dome 47D2. Second expansion layer 4332 is alsoarranged to lie in confronting relation on ceiling 496 of thirdexpansion layer 4333 and first expansion layer 4331 is arranged to liein confronting relation on second expansion layer 4332. In theillustrative embodiment of third inflatable massage bladder 433Billustrated in FIGS. 25 and 26, third inflatable massage bladder 433Bextends above expansion perimeter 461P of first inflatable lumbarbladder 421 a first distance 401 when third inflatable air bladder 433Bis in the deflated state. In another embodiment, the third inflatablemassage bladder is arranged to lie below an expansion perimeter of theinflatable lumbar bladder when the third inflatable massage bladder isin the deflated state.

In comparison, third inflatable massage bladder 433B is in an inflatedstate as a result of pressurized air stream 36 from manifold 30 beingturned ON. Pressurized air moves third expansion layer 4333 away fromfirst dome 47D2 of second monolithic sheet 442. At the same time,pressurized air 36 moves through passageway 478 from first massagechamber 456 to second massage chamber 458 to cause second expansionlayer 4332 to move away from third expansion layer 4333 and assume aconcave shape that faces upwardly and to cause first expansion layer4331 to move away from second expansion layer 4332 and assume a convexshape that faces upwardly. When third inflatable massage bladder 433B isin the inflated state, third inflatable massage bladder 433B extendsabove expansion perimeter 461P of first inflatable lumbar bladder 421 arelatively larger second distance 402 as shown in FIG. 26.

Cushion 414 is illustratively formed in a series of steps as suggestedin FIGS. 27-30. In one illustrative cushion-manufacturing process, firstmonolithic sheet 441 is formed to include several upstanding domes 46D1,46D2 and several shells 461A, 462A, 463A, 464A (in phantom) as shown inFIG. 28. Second monolithic sheet 442 is formed to include severaldownwardly extending domes 47D1, several downwardly extending moats 4M1,and several upwardly extending domes 47D2 as illustrated in FIG. 28.Next, first and second monolithic sheets 441, 442 are mated together(e.g., joined and welded) to form first and second lumbar bladders 421,422, and first and second bolster bladders 423, 424 as shown in FIG. 29.

In a separate massage-bladder manufacturing process, third extensionlayer 4333 is joined to second extension layer 4332 so that passageway478 is established. Next, first extension layer 4331 and secondextension layer 4332 are mated together at their associated perimeters4331P, 4332P so that an inflatable massage bladder is establish as shownin FIG. 30. In a final step, inflatable massage units 431, 432, 433,434, 435, 436, 438, 439, 440 are coupled to second monolithic sheet 442as suggested in FIG. 29 and a cushion is established by coupling hoses430H to associated inflatable bladder 421, 422, 423, 424, 430B as shownin FIG. 27. Seat back 412 is finally established when cushion cover 420and cushion 414 are mated with seat pan 425 as suggested in FIG. 27.

An occupant-support base 412 for a vehicle seat 410 illustrativelyincludes a cushion 414 as suggested in FIG. 22. Cushion 414 includes adeformable elastic bed 416 made of an elastomeric material and adaptedto support a portion of an occupant P seated on cushion 414 and a firstinflatable air bladder 421 coupled to deformable elastic bed 416. Firstinflatable air bladder 421 is formed to include a first air chamber 471and a first air-intake port 448 opening into first air chamber 471.

First inflatable air bladder 421 is made of the elastomeric material andconfigured to expand from a deflated state characterized by a firstvolume of air in first air chamber 471 to an inflated statecharacterized by a relatively greater second volume of air in first airchamber 471 in response to admission of pressurized air 36 into firstair chamber 471 through the first air-intake port 448.

As an example, first inflatable air bladder 421 includes inner and outershells 461A, 461B made of the elastomeric material and arranged tocooperate to define first air chamber 471 therebetween. Inner shell 461Aincludes an inner plate 479 p and an outwardly projecting dome 76coupled to inner plate 479 p and arranged to extend away from innerplate 479 p and into first air chamber 471 to support outer shell 461Bthereon in the deflated state of first inflatable air bladder 421. Outershell 461B is arranged to separate from outwardly projecting dome 76 ofinner shell 461A in the inflated state of first inflatable bladder 421,and outwardly projecting dome 76 of inner shell 461A is configured toprovide means for yieldably urging outer shell 461B away from innerplate 479 p of inner shell 461A in the deflated state of firstinflatable air bladder 421 to block bottoming-out mating contact ofouter shell 461B on inner plate 479 p of inner shell 461A duringexposure of first inflatable air bladder 421 to an exterior load causedby occupant P seated on cushion 414.

461A As shown in FIGS. 23 a to 24 a, outer shell 461B includes outerplate 469 p and laterally spaced-apart first and second outwardlyprojecting domes 47D2 coupled to outer plate 469 p and interconnected bya central pliable portion 469 pc of outer plate 469 p. Central pliableportion 469 cp of outer plate 469 p is draped over outwardly projectingdome 46D2 of inner shell 461A to position outwardly projecting dome 46D2of inner shell 461A to lie in a space 470 provided between the laterallyspaced apart first and second outwardly projecting domes 47D2 of outershell 461B in the deflated state of first inflatable bladder 421.Central pliable portion 469 pc of outer plate 469 p is separated frominner plate 461A and outwardly projecting dome 46D2 of inner shell 461Ato position outwardly projecting dome 46D2 of inner shell 461A to lieoutside of space 470 provided between laterally spaced apart first andsecond outwardly projecting domes 47D1 of outer shell 461B in theinflated state of first inflatable bladder 421.

Cushion 414 comprises a bladder system 4BS coupled to deformable elasticbed 416 and configured to include first inflatable bladder 421 and aninflatable first massage bladder 431B associated with first inflatablebladder 421. First massage bladder 431B is formed to include a firstmassage air chamber 4561 and a first massage air-intake port 476 openinginto first massage air chamber 4561. Inflatable first massage bladder431B is configured to expand from a deflated state characterized by afirst volume of air in first massage air chamber 4561 to an inflatedstate characterized by a relatively greater second volume of air infirst massage air chamber 4561 in response to admission of pressurizedair 36 into first massage air chamber 4561 through first massageair-intake port 4761. Inflatable first massage bladder 431B is coupledto first inflatable bladder 421 to move therewith relative to deformableelastic bed 416 in response to inflation and deflation of firstinflatable bladder 416.

Bladder system 4BS further includes an inflatable second massage bladder432B associated with inflatable air bladder 421 and arranged to lie inspaced-apart relation to inflatable first massage bladder 431B.Inflatable second massage bladder 432B is associated with firstinflatable bladder 421 and formed to include a second massage airchamber 4562 and a second massage air-intake port 4762 opening intosecond massage air chamber 4562. Inflatable second massage bladder 432Bis configured to expand from a deflated state characterized by a firstvolume of air in second massage air chamber 4562 to an inflated statecharacterized by a relatively greater second volume of air in secondmassage air chamber 4562 in response to admission of pressurized air 36into second massage air chamber 4562 through second massage air-intakeport 4762. Inflatable second massage bladder 432B is coupled to firstinflatable bladder 421 to move therewith relative to deformable elasticbed 461 in response to inflation and deflation of first inflatablebladder 421.

Bladder system 4BS further includes first air-supply means 4AS1 forcontrolling inflation and deflation of inflatable air bladder 421 andsecond air-supply means 4AS2 independent of first air-supply means 4AS1for controlling inflation and deflation of inflatable first and secondmassage bladders 431B, 432B independent of inflation and deflationstatus of inflatable air bladder 421 to inflate each of first and secondmassage bladders 431B, 432B alone or in combination to assume staticpressure levels in first and second massage air chambers 4561, 4562 atthe option of a passenger seated on occupant-support base 412 againstcushion 414 and to inflate and deflate first and second massage bladders431B, 432B in sequence in accordance with a selected inflation/deflationcycling plan to provide a massaging sensation to a seated passenger atthe option of the passenger seated on occupant-support base 412 againstcushion 414.

Cushion 414 comprises a monolithic first sheet 431 made of theelastomeric material and configured to include inner shell 461A andinner portions of the deformable elastic bed 461. A monolithic secondsheet 432 made of the elastomeric material and configured to includeouter shell 461B and outer portions of the deformable elastic bed 416and a massage unit 431 arranged to mate with outer shell 461B ofmonolithic second sheet 432 to form first massage air chamber 4561therebetween. Massage unit 431 lies above outer shell 461B of monolithicsecond sheet 432 and in spaced-apart relation to inner shell 461A ofmonolithic first sheet 431 to locate outer shell 461B of monolithicsecond 432 sheet therebetween.

Deformable elastic bed 416 includes a central backrest bed section 492and left-wing and right-wing bed sections 491, 493 lying in spaced-apartdiverging relation to one another to locate central backrest bed section492 therebetween and to diverge in a direction extending away fromcentral backrest bed section 492, first inflatable air bladder 421 is aninflatable lumbar bladder 421 arranged to extend into a centralbladder-receiving cavity formed in central backrest bed 492. Bladdersystem 4BS further includes a left bolster bladder 424 arranged to liein a left bladder-receiving cavity formed in left-wing bed section 491and a right bolster bladder 423 arranged to lie in a rightbladder-receiving cavity formed in right-wing bed section 493 and eachof the left and right bolster bladders 423, 424 is formed to include anair chamber and an air-intake port opening into said air chamber.

Cushion 214, 314, 414 provides support to passengers when inflatable airbladders 221, 222, 321, 322, 421, 422, 431B, 432B, 433B, 434B, 435B,436B, 438B, 439B, and 440B are in the deflated state. Support isprovided by deformable elastic bed 216, 316, 416. As an example,deformable elastic bed 216, 316, 416 is formed to include a plurality ofdownwardly extending domes 66, 466 and upwardly extending domes 76, 476.In some embodiments, downwardly extending domes 66 and upwardlyextending domes 76 mate to form resilient deformable posts 82 that maylie below inflatable air bladders 221, 222 and 321, 322.

In other embodiments, downwardly extending domes 47D1 and upwardlyextending domes 46D1 may mate to form resilient deformable posts 482 insome portions of cushion 414. In other portions of cushion 414, upwardlyextending domes 47D2, 46D2 may extend substantially the entire thicknessof cushion 414 and not mate with any downwardly extending domes 46D1.These free-standing upwardly extending domes 47D2 may lie in inflatablelumbar bladders 421, 422 and in inflatable bolster bladders 423, 424 andon inflatable lumbar bladders 421, 422.

Manufacturing efficiency of cushions 14, 114, 214, 314, 414 is maximizedas a result of cushions 14, 114 being formed by mating two monolithicsheets together, cushions 214, 314 being formed by mating threemonolithic sheets together, and cushion 414 being formed by mating twomonolithic sheets together and several separately manufacturedinflatable massage bladders. Manufacturing efficiency of vehicle seats10, 110, 210, 310 and 410 is maximized as result of integrating thedeformable elastic bed and the inflatable air bladders into cushions 14,114, 214, 314, and 414. Seat manufacturing is maximized as a result ofminimizing the complexity and the number of components comprisingvehicle seats 10, 110, 210, 310, 410.

Cushions 114 and 314 include first and second inflatable air bladders121, 122 and 321, 322. Each of the inflatable air bladders included incushions 114, 314 includes a left-wing section, a right-wing section,and a backrest section. The left-wing sections, right-wing sections, andbackrest sections provide the passenger maximized adjustable support.Inflatable air bladders 121, 122 and 321, 322 cooperate to establish anassociated pneumatically adjustable passenger support module 118 and 218that maximizes support for a passenger's torso.

Use of inflatable air bladders included in cushions 114, 314 by thepassenger is simplified as a result of left-wing section, right-wingsection and backrest section being coupled together in fluidcommunication with one another. As a result, inflation of the inflatableair bladders by the passenger causes the left-wing section, theright-wing section, and the backrest section to inflate at the sametime. It is within the scope of this disclosure to control inflation anddeflation of each left-wing section, right-wing section, and backrestsection included in the inflatable air bladders. In comparison, optimaluse of inflatable bladders 421, 422, 423, 424, 430 by the passenger isprovided as a result of each bladder being controlled separately fromevery other bladder.

The invention claimed is:
 1. An occupant-support base for a vehicleseat, the occupant-support base comprising a cushion including adeformable elastic bed made of an elastomeric material and adapted tosupport a portion of an occupant seated on the cushion, a firstinflatable air bladder coupled to the deformable elastic bed and formedto include a first air chamber and a first air-intake port opening intothe first air chamber, and a bladder support coupled to the deformableelastic bed and arranged to underlie the first inflatable air bladder,wherein the bladder support is defined by an inner shell including aninner plate and an outwardly projecting dome coupled to the inner plateand arranged to extend away from the inner plate toward the firstinflatable air bladder, the first inflatable air bladder is made of theelastomeric material and configured to expand from a deflated statecharacterized by a first volume of air in the first air chamber to aninflated state characterized by a relatively greater second volume ofair in the first air chamber in response to admission of pressurized airinto the first air chamber through the first air-intake port, the firstinflatable air bladder includes an outer shell and an auxiliary sheetmade of elastomeric material and arranged to cooperate to define thefirst air chamber therebetween, the outer shell includes an outer plateand an inwardly projecting dome coupled to the outer plate and arrangedto extend away from the outer plate and the auxiliary sheet, the outerplate is arranged to support the auxiliary sheet thereon in the deflatedstate of the first inflatable air bladder, the auxiliary sheet isarranged to separate from the outer plate in the inflated state of thefirst inflatable bladder, and the outwardly projecting dome of the innershell and the inwardly projecting dome of the outer shell cooperate toform a resilient deformable post to block bottoming-out mating contactof the outer plate of the outer shell on the inner plate of the innershell during exposure of the first inflatable air bladder to an exteriorload caused by an occupant seated on the seat cushion.
 2. Theoccupant-support base of claim 1, further comprising a seat pan arrangedto lie alongside the cushion and wherein the inner shell of the firstinflatable air bladder is retained in a fixed position on the seat pan.3. The occupant-support base of claim 2, wherein the cushion comprises amonolithic first sheet made of the elastomeric material and configuredto include the inner shell and inner portions of the deformable elasticbed and a monolithic second sheet made of the elastomeric material andconfigured to include the outer portions of the deformable elastic bedand wherein the outer shell of the monolithic second sheet is arrangedto mate in sealing relation with the auxiliary sheet to form the firstair chamber therebetween.
 4. The occupant-support base of claim 3,wherein the outer portions of the deformable elastic bed included in themonolithic second sheet cooperate to form a bladder-receiving cavityreceiving at least a portion of the first inflatable air bladdertherein.
 5. The occupant-support base of claim 3, further comprising aseat pan arranged to lie alongside the cushion and wherein the innershell and the inner portion of the deformable elastic bed is retained ina fixed position on the seat pan.
 6. The occupant-support base of claim3, further comprising a seat pan arranged to lie alongside the cushionand wherein the monolithic second sheet is arranged to lie inspaced-apart relation to the seat pan to locate the monolithic firstsheet therebetween.
 7. The occupant-support base of claim 1, wherein thedeformable elastic bed is formed to include a left-wing bed sectionalong one side of the cushion, a right-wing bed section along anopposite side of the cushion, and a backrest bed section located betweenand in angled relation to each of the left-wing and right-wing bedsections, and the first inflatable air bladder is coupled to thebackrest bed section and arranged to extend into the left-wing andright-wing bed sections are arranged to diverge in a direction extendingaway from the backrest bed section, a bladder-receiving cavity formed inthe backrest bed section to lie between the left-wing and right-wing bedsections.
 8. The occupant-support base of claim 7, further comprising aseat pan arranged to lie alongside the cushion and wherein theleft-wing, right-wing, and backrest bed sections of the deformableelastic bed are retained in fixed positions on the seat pan and theinner shell of the bladder support is retained in a fixed position onthe seat pan.
 9. The occupant-support base of claim 1, wherein thedeformable elastic bed is formed to include a left-wing bed sectionalong one side of the cushion, a right-wing bed section along anopposite side of the cushion, and a backrest bed section located betweenand in angled relation to each of the left-wing and right-wing bedsections, the left-wing and right-wing bed sections are arranged todiverge in a direction extending away from the backrest bed section, theinner shell further includes an outwardly projecting left-side domecoupled to the inner plate, the outer shell further includes an inwardlyprojecting left-side dome coupled to the outer plate and arranged to liein a left bladder-receiving cavity formed in the left-wing bed sectionand extend away from the outer plate toward the outwardly projectingleft-side dome of the inner shell, the inwardly and outwardly projectingleft-side domes cooperate to form a resilient deformable post associatedwith the left-wing bed section of the deformable elastic bed to blockbottoming-out mating contact of the outer plate of the outer shell onthe inner plate of the inner shell during exposure of the left-wingbladder section of the first inflatable air bladder to an exterior loadcaused by an occupant seated on the cushion, and the auxiliary sheet anda left-side portion of the outer shell including the inwardly projectingleft-side dome cooperate to form therebetween a left-side subchamber ofthe first air chamber.
 10. The occupant-support base of claim 1, whereinthe deformable elastic bed is formed to include a left-wing bed sectionalong one side of the cushion, a right-wing bed section along anopposite side of the cushion, and a backrest bed section located betweenand in angled relation to each of the left-wing and right-wing bedsections, the left-wing and right-wing bed sections are arranged todiverge in a direction extending away from the backrest bed section,wherein the inner shell further includes an outwardly projectingright-side dome coupled to the inner plate, the outer shell furtherincludes an inwardly projecting right-side dome coupled to the outerplate and arranged to lie in a right bladder-receiving cavity formed inthe right-wing bed section and extend away from the outer plate towardthe outwardly projecting right-side dome of the inner shell, theinwardly and outwardly projecting right-side domes cooperate to form aresilient deformable post associated with the right-wing section of thedeformable elastic bed to block bottoming-out mating contact of theouter plate of the outer shell on the inner plate of the inner shellduring exposure of the right-wing bladder section of the firstinflatable air bladder to an exterior load caused by an occupant seatedon the cushion, and the auxiliary sheet and a right-side portion of theouter shell including the inwardly projecting right-side dome cooperateto form therebetween a right-side subchamber of the first air chamberassociated with the right-wing bed section of the deformable elasticbed.
 11. The occupant-support base of claim 10, wherein the inner shellfurther includes an outwardly projecting left-side dome coupled to theinner plate, the outer shell further includes an inwardly projectingleft-side dome coupled to the outer plate and arranged to lie in a leftbladder-receiving cavity formed in the left-wing bed section and extendaway from the outer plate toward the outwardly projecting left-side domeof the inner shell, the inwardly and outwardly projecting left-sidedomes cooperate to form a resilient deformable post associated with theleft-wing bed section of the deformable elastic bed to blockbottoming-out mating contact of the outer plate of the outer shell onthe inner plate of the inner shell during exposure of the left-wingbladder section of the first inflatable air bladder to an exterior loadcaused by an occupant seated on the cushion, the auxiliary sheet and aleft-side portion of the outer shell including the inwardly projectingleft-side dome cooperate to form therebetween a left-side subchamber ofthe first air chamber associated with the left-wing section of thedeformable elastic bed, the auxiliary sheet and a central portion of theouter shell including the inwardly projecting dome cooperate to formtherebetween a central subchamber of the first air chamber associatedwith the central backrest bed section and arranged to interconnect andprovide fluid communication between the left-side and right-sidesubchambers of the first air chamber.